Dynamic Process Behavior in Laser Chemical Micro Machining of Metals

Mehrafsun, Salar; Messaoudi, Hamza

doi:10.3390/jmmp2030054

Cited by 10 publications

(19 citation statements)

References 18 publications

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“…Analogous to the assumptions in [9], different size ranges of the bubbles were detected during the machining of Ceramics and Titanium, compare Figure 3 and Figure 9. This points to two different types of bubbles, process bubbles and boiling bubbles.…”

Section: Discussionsupporting

confidence: 61%

“…If one considers the different processing regimes based on the definitions in [9], marked in Figure 13, no bubbles are formed if the ablation is not visible. In this case, the surface temperatures are not sufficient to locally break up the passive layer and initiate the chemical reactions necessary for ablation.…”

Section: Discussionmentioning

confidence: 99%

“…The process window of the laser chemical machining is strongly influenced by a variety of parameters [7], such as laser power, flow rate of the electrolyte, machining speed that is why irregularities of the ablation can occur when leaving the process window [8]. Since laser chemistry is mainly a temperature-dependent process, the quality of the ablation generated is mainly dependent on electrolyte boiling, along with the boiling bubble size and the dynamic behavior of the boiling bubbles [9].…”

Section: Introductionmentioning

confidence: 99%

“…Representation of the time during which the workpiece surface is covered by bubbles, including the removal regimes from[9].…”

mentioning

confidence: 99%

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Influence of Laser-Induced Bubble Formation on Laser Chemical Machining

Simons¹,

Radel²,

Kajsaravally³

et al. 2020

JSEMAT

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Laser Chemical Machining (LCM) is a non-conventional processing method, which enables very accurate and precise ablation of metallic surfaces. Material ablation results from laser-induced thermal activation of heterogeneous chemical reactions between electrolytes and a metallic surface. However, when processing metallic surfaces with LCM, large fluctuations in ablation quality can occur due to rising bubbles. The formation of bubbles during laser chemical machining and their influence on the ablation quality has not been investigated. For a more detailed investigation of the bubbles, ablation experiments on Titanium and Ceramic under different thermal process conditions were performed. The experiments were recorded by a high-speed camera. The evaluation of the video sequences was performed using Matlab. The resulting bubbles were analyzed regarding their size and frequency. The results show that boiling bubbles formed on both materials during processing. Titanium also produces smaller bubbles, which can be identified as process bubbles according to their size. Furthermore, it was found that undisturbed laser chemical ablation can be achieved in the presence of a boiling process, since both boiling bubbles and process bubbles were detected during machining within the process window.

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Section: Discussionsupporting

confidence: 61%

Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…Representation of the time during which the workpiece surface is covered by bubbles, including the removal regimes from[9].…”

mentioning

confidence: 99%

See 2 more Smart Citations

Influence of Laser-Induced Bubble Formation on Laser Chemical Machining

Simons¹,

Radel²,

Kajsaravally³

et al. 2020

JSEMAT

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“…The adhering bubble can act like a scattering center and deflect a part of the incoming laser beam to its periphery (light deflection effect). While the shielding effect results in a reduced removal depth and the deposition of metal salts and oxides, the light reflections lead to a broadening or a dislocation of the removal cavity [Meh18].…”

Section: Process Fundamentalsmentioning

confidence: 99%

Tooling

Vollertsen

Seven

Messaoudi

et al. 2019

Lecture Notes in Production Engineering

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Micro metal parts are usually produced in large lot sizes at high production rates. In order to achieve sufficient product quality, excessive tool wear has to be avoided. In the micro range, so-called scaling effects and their influence on tool wear in micro forming have not been investigated so far. For the investigation, tests in micro deep drawing were carried out with metal sheets (s < 50 μm) of pure aluminum Al99.5, a copper alloy E-Cu58 and stainless steel 1.4301. The failure mechanisms of the micro cups produced were identified as bottom fracture and cup wall damage, and tool wear was measured and characterized with optical measurements and EDX analyses. Moreover, micro cups can be produced by DLC-and PVD-coated tools in a dry forming process. To investigate the wear behavior in a continuous process, a forming tool was developed with an integrated blanking and deep drawing die. The tool wear was measured optically, and the wear mechanisms could be identified in a combined micro and deep drawing process. As a result, the tool could be modified by a manufacturing in selective laser melting and the tool life increased by 290%. Furthermore, a method for tool wear examination in long-term tests was developed. In lateral micro upsetting, the tool wear history can be examined by analyzing the formed product. Several tool materials and coatings were tested with up to 500,000 strokes.

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Extension of the Process Window in Laser Chemical Machining by Temperature-Dependent Reduction of the Electrolyte Viscosity

Simons

Radel

Vollertsen

2021

Int. J. Precis. Eng. Manuf.

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The laser chemical process is a material-removing machining process in the micro range. The process is based on a laser-assisted etching process between an electrolyte and a metallic workpiece. Local overheating causes a laser-induced electrolyte boiling process, which limits the laser chemical process window. In order to reduce the laser-induced electrolyte boiling process and thus expand the process window, the laser chemical process is carried out at different electrolyte start temperatures and thus different electrolyte viscosities and surface tensions. The experimental investigations were carried out on Titanium Grade 1 with the electrolytes phosphoric acid and sulfuric acid at different electrolyte temperatures and laser powers to determine the limits of the process window by evaluating the properties of the removal cavities. As a result, the process window is extended at lower electrolyte viscosities. Thereby, the electrolyte viscosities have no influence on the geometric shape of the removal. The extension of the process window is attributed to the fact that a reduction in electrolyte viscosity results in a less pronounced formation of the boiling process, the bubble diameters decrease, and the shielding effect of the bubbles is reduced.

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Dynamic Process Behavior in Laser Chemical Micro Machining of Metals

Cited by 10 publications

References 18 publications

Influence of Laser-Induced Bubble Formation on Laser Chemical Machining

Influence of Laser-Induced Bubble Formation on Laser Chemical Machining

Tooling

Extension of the Process Window in Laser Chemical Machining by Temperature-Dependent Reduction of the Electrolyte Viscosity

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