Laser powder forming, also known by the proprietary name laser engineered net shaping is an additive manufacturing technology developed for fabricating metal parts directly from a computeraided design cad solid model by using a metal powder injected into a molten pool created by a focused, highpowered laser beam. This technique is applied to flatten a protruded distortion on the sheet metal and the results investigated experimentally. Laser forming lf evolved from more mature, but less sophisticated thermomechanical forming processes. Development of a local threedimensional numerical simulation model for the laser forming process of aluminium components g. The precision of the laserinduced stress enables exact prediction and. Laser forming and welding processes materials forming. The forming potential of stainless steel 1 introduction stainless steel has considerable potential in forming applications, due to its interesting range of mechanical properties. Laser forming and welding processes materials forming, machining and tribology kindle edition by yilbas, bekir sami, akhtar, sohail, shuja, shahzada zaman.
Laser forming laser forming has become a viable process for the shaping of metallic components, as a means of rapid prototyping and of adjusting and aligning. In order to seek the optimal process conditions to generate a desired bend angle in the multiscan laser bending process, an optimization algorithm based on the approximation of objective function and state variables is integrated into the numerical model. Relevant industry sectors include aerospace, automotive, and microelectronics. Pdf process designing for laser forming of circular. The main driving force of rapid prototyping rp or layer manufacturing techniques changed from fabrication of prototypes to rapid tooling rt and rapid manufacturing rm. An experimental investigation on passive water cooling in laser forming process. Comparative study of numerical models of the laser forming process alberto torres cruz, dirk f. Mixeddimensional coupling modeling for laser forming process. Laser forming lf is a nontraditional forming process that does not require hard tooling or external forces and hence, dramatically increases process flexibility and can reduce the cost of forming processes. Pdf an experimental investigation on passive water. Laboratory of technology and strength of materials, department of mechanical engineering and aeronautics, university of patras, rion 26500, greece article info article history. Deformation, microstructure, hardness, and pitting corrosion of 316 stainless steel after laser forming. In contrast with conventional forming techniques this method requires no mechanical contact and hence offers many of the advantages of process flexibility associated.
Laser forming lf is a highly flexible rapid prototyping and lowvolume manufacturing process, which uses laserinduced thermal distortion to shape sheet metal parts without hard tooling or external forces. Efficient laser forming modeling for industrial application is still in the developing stage and many researchers are in the process of modifying it. The materials high strengthtoweight ratio and considerable elongation and work hardening properties mean it can often meet the challenges of complex, three. Our inhouse teams work together closely to provide the breadth of technical insight our partners need to consider which highprecision laser systems are right for their application from pipelines to nuclear storage containers to pacemakers. Laser welding is a process used to join together metals or thermoplastics using a laser beam to form a weld. It consists in the production of full strength metallic engineering components using a threedimensional laser cladding process. Conventional threedimensional finite element models are still expensive on computational time. Parametric studies of vacuum assisted laser forming. Process designing of laser forming involves finding a set of process. After laser forming, the shape of the sheet material will be changed, as shown in figure 2ac. Laser forming and welding processes bekir sami yilbas. Effects of clamping on the laser forming process although considerable effort has gone into characterizing the laser forming process in terms of process parameters and conditions, there has been little emphasis on the effects of the mechanical and thermal constraints introduced by the clamping method utilized for a desired application.
They have observed that under the processing conditions of tgm, the plate bends not only about the xaxis but also about the yaxis. The effect of passive water cooling in laser forming of thin sheets made of aisi 304 stainless steel is experimentally investigated. Computational laser forming origami yue hao and jyhming lien laser forming is a fabrication method that uses a laser to fold sheets into 3d structures. A comparison between natural and forced cooling volume 32 issue 16. Introduction laser forming has become a viable process for the shaping of metallic components, as a means of rapid prototyping and of adjusting and aligning. Laser forming is fast emerging as a viable means for the shaping of metallic components, as a means of rapid prototyping and of adjusting and aligning. The use of a laser beam in forming processes was introduced at the end of 20th century and is still under development.
We also provide quick setups and low tooling costs, making fabrication of prototype projects and lowvolume runs feasible and costeffective. Laser cutting is able to cut faster and with a higher quality then competing processes. During this process, the laser beam melts the material and also creates a deep steam capillary also called keyhole with approximately 1. Laser forming, a nontraditional manufacturing process, does not require any externally applied forces to generate desired forms. The laser cutting process uses a focused laser beam and assist gas to sever metallic plate with high accuracy and exceptional process reliability. A schematic of the laser forming process is shown in figure 1. The laser beam forming process lbf one of the determined criteria in the choice of a suitable manufacturing process is the sustainability of the influence on the cost, its effect on the environment and operators, and its flexibility with other modern systems and applications to engineering need.
Advances in laser forming journal of laser applications. Each transformation or laser process is controlled by precisely regulating the wavelength, power, duty cycle and repetition rate of the laser beam. Pdf laser forming and welding processes researchgate. This book introduces model studies and experimental results associated with laser forming and welding such as laser induced bending, welding of sheet metals, and related practical applications. The process is similar to the well established torch flame bending used on large sheet material in the ship building industry but a great deal more control of the final product can be achieved. Pdf process designing for laser forming of circular sheet metal. This overview will focus on the direct fabrication of metal components by using laserforming techniques in a layerbylayer fashion. Deformation, microstructure, hardness, and pitting. The laser forming process is realised by introducing thermal stresses into the surface of a workpiece. Rapid manufacturing of metal components by laser forming. The laser process can generate deep compressive stresses to shape even thick components without inducing unwanted tensile stress at the metal surface. Download it once and read it on your kindle device, pc, phones or tablets. The book provides insight into the physical processes involved with laser forming and welding. The laser beam makes forming technology applicable for industrial use, which formerly had to be done manually due to the lack of reproducibility or flexibility of the heat source used e.
The end products of forming processes can either be final components or basic shapes such as rods, bars, tubes, sheets, plates, etc. The objective of the nistsponsored project laser forming of complex structures is to develop technologies for controllable, repeatable laser forming processes that shape and re. Laser forming process optimization and material sensitivity are investigated. The objective of the nistsponsored project laser forming of complex structures is to develop technologies for controllable, repeatable laser forming processes that shape. Laser forming is a new type of flexible manufacturing process that has become viable for the shaping of metallic components. Its basic feature is the forming by thermal stresses, induced by irradiation of a laser beam. The process can be easily automated with good prospects for adaptive. Laser forming refers to a process by which the laser beam is irradiated and passed through a sheet surface and, as a result of the movement of the laser beam on the surface and generation of heat. Numerical study of the mechanism of laser forming process.
We utilize our laser peening process to form and shape the contour of metal components such as wing skins. The deeper compressive stress achieved by laser peening allows the formation of thicker sections and tighter curvatures. The protrusion of some height is intentionally produced by pressing a steel ball on a. If you are ever in need of an innovative company that loves a challenge and will value your business, pdf, inc. Laser forming of complex structures columbia university. Us6410884b1 contour forming of metals by laser peening. This is the main advantage it has over its traditional counterparts, as the hard tooling process has been eliminated from the overall process flow. In the present context, forming process is primarily referred to as sheet material forming such as bending. How the laser cutting process works spi lasers overview. Laser cutting is a highly accurate process, thanks to this high level of control that you are offered. Use features like bookmarks, note taking and highlighting while reading laser forming and welding processes materials forming, machining and tribology.
Experimental investigation of laser beam forming of. A method and apparatus are provided for forming shapes and contours in metal sections by generating laser induced compressive stress on the surface of the metal workpiece. The effects of anisotropy on the laser forming process, however, have not been studied in detail, while most sheet. Pdf laser forming and welding processes can meet the industry demands associated with advantages such as precision of operation, low. Laser forming is classified as a nontraditional manufacturing process, as it does not require any externally applied forces to generate desired forms. The intensity of the laser radiation is around 1 mw per square centimeter. The laserbased metal forming process is a technique that has the potential to produce fully functional models directly from a cad system and eliminate the need for an intermediate step.
Laser forming of complex structures semantic scholar. Mostly, the attention on laser beam forming has been focused on laser forming along linear irradiation paths, and the sheets employed in the. A study on laser forming processes with finite element analysis. Laser metal fornling lmf is an innovative application for lasers with industrial potential for small series production, rapid prototyping, or repair engineering. Laser forming process is a new flexible forming process without any contact between rigid tools and sheet metal, in which the form of a sheet metal is changed permanently by high thermal stresses.
Highintensity laser beams can be used to heat and bend sheet metal, but the mechanisms of the laser forming lf process are not well understood or precisely controllable. Being such a concentrated heat source, in thin materials laser welding can be carried out at high welding speeds of metres per minute, and in thicker materials can produce narrow, deep welds between squareedged parts. Laser metal forming processes for rapid prototyping a. The glass of a glass preproduct may be heated to be formed, a laser may be used that emits light having a wavelength for which the glass of the glass preproduct is at most partially transparent so that the light is at least partially absorbed in the glass. Laser beam forming with thermal stresses has been known for several years and is gradually coming out of the developmental stage 17. Although considerable effort has gone into characterizing the laser forming process in terms of process parameters and conditions, there has been little emphasis on the effects of the mechanical. To overcome the limitations in the traditional practice that relies on tedious manual design, this work advances laser forming by developing computational methods that procedurally convert a polyhedron p into laser formable 2d patterns and. These internal stresses induce plastic strains, bending or shortening the material, or result in a local elastic plastic buckling of the work piece depending on the mechanism active3. Indeed, since each laser scan can produce only small bending angles, multiple laser scans are required to produce a.
Pdf effects of clamping on the laser forming process. The principle of the process is that the laser beam is. Reducing the adjustment complexity during the forming of glass products, such as the forming of glass tubes to obtain syringe bodies. Comparative study of numerical models of the laser forming. Laser forming and welding processes can meet the industry demands associated with advantages such as precision of operation, low cost, and local treatment. Laser forming is a complex dynamic forming process. The deep, high magnitude compressive residual stresses induced by laser peening increase the resistance of materials to surfacerelated failures, such as fatigue, fretting fatigue and stress corrosion cracking.
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