Path Calculation of 7-axes Synchronous Quasi-Tangential Laser Manufacturing

Abstract

Quasi-tangential laser processing, also called laser turning is increasingly applied for various applications. Specifically, its ability to generate complex geometries with small feature sizes at high precision and surface quality in hard, brittle and electrically non-conductive materials. Due to the geometric flexibility, the process is well suited for prototyping in hard-to-machine materials such as ceramics, carbides and super-abrasives. However, the lack of advanced software solutions for this novel process hitherto limited the exploitation of this potential. Here, we discuss a unique computer-aided manufacturing approach for synchronous 7axis laser manufacturing with quasi-tangential strategies. This gives the peerless possibility to process arbitrary geometries, which cannot be manufactured with conventional techniques. A detailed description of the path calculation with derivation and procedures is given. The generated machine code is tested on a 7-axis laser manufacturing setup. Following, a processed cylindrical ceramic specimen with a continuously varying profile along a helical path is presented. The profile is constituted by a rectangular over half-spherical to a triangular groove with defined pitch. This demonstrator provides the validation of this CAM solution. Measurements of the produced specimen show high adherence with the target geometry with an average deviation below 10 µm.profile on a helical pitch within the physical limitations of laser processing can be produced. After a detailed discussion of the necessary functionality of the CAM solution the experimental result is presented as validation of this unique concept. CAM Modules 70There are general approaches on CAM programming for various manufacturing techniques like milling [20], drilling and grinding [21]. However, laser manufacturing has to be treated differently, taking into account the non-binary behavior with the workpiece [22]. The interaction of the laser beam with the material depends on several parameters with non-linear behavior. The most 75 influencing dependencies concern the laser wavelength λ, polarization P , pulse duration τ P , fluence F , angle of incidence θ i , the materials susceptibility χ and

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