Ultrasonic Vibration-Assisted Laser Cutting Head

Team Members:
Abdulrahman Asiri
Ben Brunty
Shafiq Mohd Rahim
Almahdi Mohsin
Muhaimin Ruslan
Project Advisor: Dr. Wenda Tan
 Outline

● Problem statement

● CFP explanation and motivation

● Test/Evaluation setup

● Budget

● Future work

● Summary

● Questions and answers

What is Laser Cutting?

Figure 1.
 What is Dross and Striation?

Striations

Figure 2. Workpiece cut surface

Dross
 Solution

● Vibration

○ Vertical vibration

○ Oscillating the focal position

○ Slowing down solidification of molten part

 System Overview

Fig 3. Schematic illustration of the Proposed system

 Compare different designs

Linear Actuator Mechanism Impact design vibrating mechanism

Figure 4. Figure 5.
 Compare different designs

Concepts

Linear Actuator Mechanism Impact design vibrating mechanism

Selection Criteria Weight Rating Weighted Score Rating Weighted Score

Dynamic Modelling 20% 4 0.8 3 0.6

Complexity

Affordability 10% 3 0.3 4 0.4

Speed of Oscillations 20% 4 0.8 2 0.4

Precision of Amplitude 20% 4 0.8 2 0.4

Durable 10% 3 0.3 2 0.2

Manufacturing 15% 4 0.6 1 0.15

Easy to use 5% 4 0.2 2 0.1

Total Score 3.80 2.25

Rank
 Planned CFP

● Ultrasonic Vertical Displacement

● Piezoelectric Actuator

Figure 6. Figure 7.
 Parametric Investigation

● To facilitate material removal:

○ Frequency is kept fixed at a minimum value of 20 kHz.

○ Varying the amplitude of oscillations from 0.1 - 50 µm.

Selection of actuator

Figure 8.
 Amplify vibration

● Booster and horn need to be 14.5 cm long

● Length = (speed of sound/ frequency)/2

Figure 9.

Figure 10.
 Test setup

Phase 1:

● Record amplitude and vibration with high speed camera

Phase 2:

● Cut without vibration for comparison

● Cut with frequency (20kHz) and amplitudes (0.1 - 50 m)

● Compare thickness of defects

 Budget

● Projected Funding: 2000-3000 USD

● Spent so far: 20.00 USD

● Projected Costs: 1000-2000 USD

 Future work

September 2, 2018: October 28, 2018:

● Complete Analytical Model for ● Complete laser head
CFP Test Characteristics assembly
● Order all materials for vibrating
mechanism November 11, 2018:
● Test laser head performance
September 30, 2018: by cutting composite plate
● Complete CFP manufacturing
● Finalize CAD drawing for
full-scale nozzle November 18, 2018:
● Interpret test results
October 7, 2018:
● Use high speed camera for
December 2, 2018:
vibration testing
● Revise the test results of
our design
October 14, 2018:
● Adjust vibration mechanism
based on testing
 Summary

● Reduce Dross and Striation

● Vibration is the critical function

● Comparison of concept designs

● Piezoelectric actuator

● Test constant frequency with varying amplitude

● Future work
Questions?
Works Cited

● Caristan, C. (2004). Laser cutting guide for manufacturing. Dearborn, MI: Society of Manufacturing Engineers.

● Kannatey-Asibu, E. (2009). Principles of Laser Materials Processing. John Wiley & Sons.

● Yilbas, B. S., & Aleem, B. J. (2006). Dross formation during laser cutting process. Journal of Physics D: Applied Physics, 39(7),

1451-1461. doi:10.1088/0022-3727/39/7/017

● Dahotre, N. B. (2014). Laser fabrication and machining of materials. Place of publication not identified: Springer.

● García-López, E., Medrano-Tellez, A., Ibarra-Medina, J., Siller, H., & Rodriguez, C. (2017). Experimental Study of Back Wall

● Dross and Surface Roughness in Fiber Laser Microcutting of 316L Miniature Tubes. Micromachines, 9(1), 4.

doi:10.3390/mi9010004
Works Cited

● Ion, J. C. (2011). Laser processing of engineering materials: principles, procedure and industrial application. Amsterdam etc.:

Elsevier.

● Schuöcker, D., Majer, R., & Aichinger, J. (2013). Surface tension in laser cutting and its impact on cutting performance. XIX

International Symposium on High-Power Laser Systems and Applications 2012. doi:10.1117/12.2010263

● Goppolda, C., Pindera, T., Herwiga, P., Mahrlea, A., Wetziga, A., & Beyera, E. Beam oscillation–periodic modification of the

geometrical beam properties.

● Park, J. K., Yoon, J. W., & Cho, S. H. (2012). Vibration assisted femtosecond laser machining on metal. Optics and Lasers in

Engineering, 50(6), 833-837.

● Striation-free Laser Cutting of Mild Steel Sheets LinLiM.SobihP.L.Crouse School of Mechanical, Aerospace and Civil

Engineering, The University of Manchester, UK. Available online 14 June 2007.