Material removal rates in ultra-high-speed micro machining using a picosecond laser

Author(s):  
Tero Kumpulainen ◽  
Ilpo Karjalainen ◽  
Reijo Tuokko
CIRP Annals ◽  
2001 ◽  
Vol 50 (1) ◽  
pp. 263-268 ◽  
Author(s):  
T.L. Schmitz ◽  
M.A. Davies ◽  
K. Medicus ◽  
J. Snyder

2015 ◽  
Author(s):  
M. Mainuddin ◽  
R. Keanini ◽  
B. Mullany

Although precision polishing of optical grade components using pitch based tools is still common practice, the process has not received the same level of scientific attention as other precision material removal processes. Building on previous research results, this paper demonstrates the relationship between low amplitude, broad spectrum vibrational power input and fused silica material removal rates obtained with different tool-polishing machine combinations. A low cost, easy to implement method of increasing vibrational power is presented and verified through polishing tests. The method uses small, off the shelf, high speed (>10 krpm), DC motors with eccentric masses (0.5 g and 4 g). Attachment of the battery driven motors to the underside of the platen and the workpiece holder increased the vibrational input from 0.7 W to 0.22 W resulting in an increase in the material removal rate from 0.96 mg/hr to 1.10 mg/hr. A method to attenuate process generated vibrations, and thus material removal rates, is also outlined. To achieve this the tool construction is modified by the addition of a cork layer between the substrate and the pitch layer. While this approach is not as flexible as that for increasing the vibrational power input, it successfully attenuated process vibrations (0.2 W to 0.14 W) and reduced the associated material removal rate (9.67 mg/hr to 6.13 mg/hr). The results outlined this paper demonstrate that recording and controlling process vibrations provides practitioners with viable process monitoring and optimization options.


2014 ◽  
Author(s):  
Wenwu Zhang ◽  
Junke Jiao ◽  
Liang Ruan ◽  
Tianrun Zhang

To study the characteristics of material removal with high power ultra-short pulsed lasers, a 300 W picosecond laser was used to make microgrooves in cooper and steel. The effects of laser power, laser frequency, scanning layers, and scanning velocity on the width and depth of the grooves were analyzed. The material removal rate of picosecond laser was compared with that of a 10 W nanosecond laser. The results showed that high power high frequency ultra-short pulsed lasers have good potential in high speed micromachining. Evidence showed that ps laser machining could be more efficient than nanosecond machining. There are issues to be solved to make high power ultra-short pulsed lasers the dominating process for high speed micromachining.


2008 ◽  
Vol 202 (22-23) ◽  
pp. 5613-5616 ◽  
Author(s):  
S.H. Shin ◽  
M.W. Kim ◽  
M.C. Kang ◽  
K.H. Kim ◽  
D.H. Kwon ◽  
...  

2013 ◽  
Vol 804 ◽  
pp. 17-22
Author(s):  
Ammar Melaibari ◽  
Pal Molian

Ultra-hard AlMgB14 (30-50 GPa) thin films were deposited on silicon substrate for a nominal thickness of 100 nm using a pulsed excimer laser and then subjected to direct micromachining using a 532 nm, 30 picosecond pulsed Nd:YAG laser. The application is targeted towards synthesizing an artificial nacre material composed of hexagonal bricks and particle bridges of superhard AlMgB14 thin film and mortars of Ti thin film that biomimic the hierarchical architecture of natural nacre. The effects of pulse energy (0.1 to 1 μJ) and laser scanning speed (0.5 to 1.5 m/sec) on ablation depth and quality of scribed channels were evaluated. The morphology of the channels was characterized using confocal microscope and optical profilometer. Results indicated a clean material removal process characterized by absence of heat affected zone, high-speed scribing and small feature size. The energy fluence for the removal of 100 nm thin film without affecting the silicon substrate was 0.3 J/cm2. An interesting observation is that particulate matter present in the thin film was not ablated suggesting a size effect. Analysis of thermal transport reveals that the material removal has occurred via spallation and phase explosion mechanisms. The picosecond laser thus offers a high-speed energy source for precisely ablating ultra-hard thin films that in turn will allow the potential for fabrication of novel artificial nacre with exceptional strength and toughness.


2009 ◽  
Vol E92-C (7) ◽  
pp. 922-928 ◽  
Author(s):  
Kikuo MAKITA ◽  
Kazuhiro SHIBA ◽  
Takeshi NAKATA ◽  
Emiko MIZUKI ◽  
Sawaki WATANABE

Author(s):  
Ryoken Masuda ◽  
Manabu Horiuchi ◽  
Mitsuhide Sato ◽  
Yinggang Bu ◽  
Masami Nirei ◽  
...  

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.


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