Finite element analysis and simulation of liquid-assisted laser beam machining process

Laser beam micromachining (LBMM) process is one of the important advanced manufacturing processes which can shape almost all engineering materials with micron scale precision even for complex geometries. LBMM process when performed in air generates high heat flux causing thermal damage and poor surf...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2018-02, Vol.94 (5-8), p.2325-2331
Main Authors: Mistry, Vinit, James, Sagil
Format: Article
Language:English
Subjects:
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Damage
Diameters
Engineering
Ethylene glycol
Experimentation
Film thickness
Finite element method
Heat affected zone
Heat flux
Industrial and Production Engineering
Laser beams
Lasers
Machining
Mechanical Engineering
Media Management
Micromachining
Original Article
Process parameters
Simulation
Substrates
Surface finish
Thin films
Water film
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Summary:Laser beam micromachining (LBMM) process is one of the important advanced manufacturing processes which can shape almost all engineering materials with micron scale precision even for complex geometries. LBMM process when performed in air generates high heat flux causing thermal damage and poor surface finish on the substrate material. Liquid-assisted laser beam micromachining is considered as an alternate approach to the traditional laser beam micromachining process performed under air to reduce the thermal damages caused due to high heat of laser. The presence of liquid medium also helps in carrying away the molten material from the machining zone thereby preventing re-deposition. The focus of this research is to understand the effect of critical process parameters involved in liquid-assisted laser beam micromachining using finite element simulation technique. The study revealed that the width (diameter) and depth of the heat-affected zone decreased considerably with water film thickness of 0.50 mm and higher. Further experimentation is used to validate the results of the simulation model. The experimental results closely matched with the predictions of the simulation study. Micromachining performed under thin films of water and ethylene glycol showed better surface finish as compared to machining performed without water. This suggests that the liquid medium occupies the void during material removal due to laser beam and helps reducing the thermal damage.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-017-1009-3