Multi-Material Capability of Laser Induced Plasma Micromachining

2014 ◽  
Author(s):  
Ishan Saxena ◽  
Kornel Ehmann
Keyword(s):  
Laser Ablation ◽  
Metal Cutting ◽  
Medical Engineering ◽  
Machining Process ◽  
Micro Machining ◽  
Promising Alternative ◽  
Laser Induced Plasma ◽  
Direct Laser ◽  
Micro Features ◽  
Machining Characteristics

Presently surface micro-texturing has found many promising applications in the fields of tribology, bio-medical engineering, metal cutting, and other functional or topographical surfaces. Most of these applications are material-specific, which necessitates the need for a texturing and machining process that surpasses the limitations posed by a certain class of materials that are difficult to process by laser ablation, owing to their optical or other surface or bulk characteristics. Laser Induced Plasma Micromachining (LIPMM) has emerged as a promising alternative to direct laser ablation for micro-machining and micro-texturing, which offers superior machining characteristics while preserving the resolution, accuracy and tool-less nature of laser ablation. This study is aimed at understanding the capability of LIPMM process to address some of the issues faced by pulsed laser ablation in material processing. This paper experimentally demonstrates machining of optically transmissive, reflective and rough surface materials using LIPMM. Apart from this, the study includes machining of conventional metals (Nickel and Titanium) and polymer (Polyimide), to demonstrate higher obtainable depth and reduced heat affected distortion around micro-features machined by LIPMM, as compared to laser ablation.

Multimaterial Capability of Laser Induced Plasma Micromachining

2014 ◽  
Vol 2 (3) ◽  
Author(s):  
Ishan Saxena ◽  
Kornel F. Ehmann
Keyword(s):  
Laser Ablation ◽  
Biomedical Engineering ◽  
Metal Cutting ◽  
Pulsed Laser ◽  
Pulsed Laser Ablation ◽  
Machining Process ◽  
Promising Alternative ◽  
Laser Induced Plasma ◽  
Direct Laser ◽  
Machining Characteristics

Presently surface microtexturing has found many promising applications in the fields of tribology, biomedical engineering, metal cutting, and other functional or topographical surfaces. Most of these applications are material-specific, which necessitates the need for a texturing and machining process that surpasses the limitations posed by a certain class of materials that are difficult to process by laser ablation, owing to their optical or other surface or bulk characteristics. Laser induced plasma micromachining (LIPMM) has emerged as a promising alternative to direct laser ablation for micromachining and microtexturing, which offers superior machining characteristics while preserving the resolution, accuracy and tool-less nature of laser ablation. This study is aimed at understanding the capability of LIPMM process to address some of the issues faced by pulsed laser ablation in material processing. This paper experimentally demonstrates machining of optically transmissive, reflective, and rough surface materials using LIPMM. Apart from this, the study includes machining of conventional metals (nickel and titanium) and polymer (polyimide), to demonstrate higher obtainable depth and reduced heat-affected distortion around microfeatures machined by LIPMM, as compared to laser ablation.

A comparative study of direct laser ablation and laser-induced plasma-assisted ablation on glass surface

2021 ◽  
pp. 103737
Author(s):  
Yani Xia ◽  
Xiubing Jing ◽  
Dawei Zhang ◽  
Fujun Wang ◽  
Syed Husain Imran Jaffery ◽  
...  
Keyword(s):  
Laser Ablation ◽  
Comparative Study ◽  
Glass Surface ◽  
Laser Induced Plasma ◽  
Direct Laser

Analysis of Cutting Technologies for Lightweight Frame Components

2006 ◽  
Vol 10 ◽  
pp. 121-132 ◽  
Author(s):  
Klaus Weinert ◽  
Sven Grünert ◽  
Michael Kersting
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Thermal Stresses ◽  
Machining Process ◽  
Frame Structure ◽  
Experimental Investigations ◽  
Promising Alternative ◽  
Thin Walled ◽  
Process Strategy ◽  
Conventional Drilling

Most technical components applied in industrial practice are subjected to metal cutting operations during their production process. However, this leads to undesirable thermal and mechanical loads affecting the machined workpiece, which can result in an impairment of its serviceability. Due to their small wall thickness lightweight hollow profiles are highly susceptible to the inevitable machining loads and thermal stresses during drilling processes. For the virtual optimization of the machining process and in order to ensure a suitable process strategy, a finite element simulation of cutting operations for thin-walled light metal profiles is conducted. Due to the flexibility within creating drill holes of different diameters without tool changes circular milling represents a promising alternative to the application of conventional drilling tools for variable process strategies to handle batch sizes down to one piece efficiently. Hence, this article gives an insight into the investigations regarding the modeling concepts of the mechanical and thermal loads induced into the thin-walled lightweight frame structure during the circular milling process. Furthermore, process reliability aspects as well as the correlation of the calculated and the measured results will be discussed on the basis of experimental investigations. Finally, this article compares Finite Element Analysis aspects of circular milling processes with conventional drilling processes.

Line-Based Laser Induced Plasma Micro-Machining (L-LIPMM)

2013 ◽  
Author(s):  
Rajiv Malhotra ◽  
Ishan Saxena ◽  
Kornel Ehmann ◽  
Jian Cao
Keyword(s):  
Laser Ablation ◽  
Process Parameters ◽  
Ultrashort Pulse ◽  
Experimental Setup ◽  
Micro Machining ◽  
Ultrashort Pulse Laser ◽  
Plasma Generation ◽  
Laser Induced Plasma ◽  
Laser Micro Machining ◽  
Wide Range

Recently, the technique of Spot-based Laser Induced Plasma Micro-Machining (Spot-LIPMM) has been developed to address the limitations of conventional ultrashort pulse laser micro-machining. Its main advantages are adaptability to a wide range of materials and superior wall geometries. We propose a variation of the Spot-LIPMM process by creating line plasma instead of spot plasma, with the use of suitable optics. This paper describes the experimental setup used to create line plasma and the process used for micro-machining with L-LIPMM. Optics simulations are developed as a means of guiding the choice of optics to be used for line plasma generation and estimating the energy and shape of the plasma created. It is shown that this Line-based LIPMM (L-LIPMM) process is capable of micromachining channels at a much higher speed than conventional Spot-based laser ablation or spot-based LIPMM. Additionally, the effects of process parameters on machined geometry using L-LIPMM are discussed.

scholarly journals Review on Performance Evaluation of Machining Characteristics using Vegetable-based Cutting Fluids – An approach towards Green Manufacturing

2021 ◽  
Vol 58 (2) ◽  
pp. 6358-6365
Author(s):  
Mohd. Asif I. Gandhi
Keyword(s):  
Vegetable Oil ◽  
Metal Cutting ◽  
Harmful Effect ◽  
Green Manufacturing ◽  
Machining Process ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Machining Characteristics ◽  
Disposal Cost ◽  
Lubricating Properties

Lubricants play a major role in decreasing friction and wear during the machining process. Commercial metal cutting fluids are non-renewable and also produces the harmful effect to the environment as well as the operators. The preparation and disposal cost of mineral oil is an expensive one. To promote sustainable and green manufacturing eco-friendly cutting fluid is the need of an hour. Vegetable oil is preferred as an alternative tocommercial cutting fluid owing to its environmentally friendly, biodegradability, renewable, and less toxic, as well as exceptional lubricating properties. This article discusses the influence of various vegetable oil used for the material removal process and its performance. Vegetable oils significantly enhance the machining characteristics in terms of cutting force, tool wear, and surface quality

Surface Morphology and Wall Angle Comparison of Microchannels Fabricated in Titanium Alloy Using Laser-Based Processes

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Suman Bhandari ◽  
Nicolas Martinez-Prieto ◽  
Jian Cao ◽  
Kornel Ehmann
Keyword(s):  
Laser Ablation ◽  
Surface Morphology ◽  
Wall Angle ◽  
Sem Images ◽  
Laser Induced Plasma ◽  
Technological Gap ◽  
Angle Measurements ◽  
Direct Laser ◽  
Morphological Differences ◽  
3D Scans

Abstract The increase in the usage of titanium alloys for micro-engineering applications has driven the demand for improved micromanufacturing processes. Laser-based microfabrication processes such as direct laser ablation (DLA), laser-induced plasma micromachining (LIPMM), and magnetically controlled laser-induced plasma micromachining (MC-LIPMM) are promising technologies to fill this technological gap. In this paper, we evaluate microchannels fabricated in Ti6Al4V substrates using laser ablation, LIPMM, and MC-LIPMM. Scanning electron microscope (SEM) images and 3D scans of the channels were used to compare the surface morphology and channel geometry for different feed rates and number of laser passes. Wall angle measurements show that the LIPMM processes yield channels with steeper walls and smoother walls in comparison with the channels fabricated using direct ablation. The clear morphological differences on the surface finish of the walls made by direct ablation and using laser-induced plasmas hint at the differences in material removal mechanisms between these manufacturing methods.

Laser Induced Plasma Micro-Machining

2010 ◽  
Author(s):  
Kumar Pallav ◽  
Kornel F. Ehmann
Keyword(s):  
Tool Wear ◽  
Material Removal ◽  
Machining Process ◽  
Micro Edm ◽  
Micro Machining ◽  
Workpiece Surface ◽  
Laser Induced Plasma ◽  
New Process ◽  
Explosive Expansion ◽  
Edm Process

A new micro-machining process that is motivated by the need to overcome the various limitations associated with the micro-EDM (μ-EDM) process is introduced. The limitations in μ-EDM are primarily due to the requirement of a conductive electrode and workpiece, tool wear, and complex wear compensation strategies. The new process, termed “laser-induced plasma micro-machining” uses a laser beam to generate plasma in a dielectric near the workpiece surface whose explosive expansion results in material removal by mechanisms similar to those that occur in μ-EDM.

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