Goal driven optimization of process parameters for maximum efficiency in laser bending of advanced high strength steels

Laser forming or bending is fast becoming an attractive option for the forming of advanced high strength steels (AHSS), due primarily to the reduced formability of AHSS when compared with conventional steels in traditional contact-based forming processes. An inherently iterative process, laser forming must be optimized for efficiency in order to compete with contact based forming processes; as such, a robust and accurate method of optimal process parameter prediction is required. In this paper, goal driven optimization is conducted, utilizing numerical simulations as the basis for the prediction of optimal process parameters for the laser bending of DP 1000 steel. A key consideration of the optimization process is the requirement for minimal microstructural transformation in automotive grade high strength steels such as DP 1000

Imaging-based amplitude laser beam shaping for material processing by 2D reflectivity tuning of a spatial light modulator

We have demonstrated an imaging-based amplitude laser-beam-shaping technique for material processing by 2D reflectivity tuning of a spatial light modulator. Intensity masks with 256 gray levels were designed to shape the input laser beam in the outline profile and inside intensity distribution. Squared and circular flattop beam shapes were obtained at the diffractive near-field and then reconstructed at an image plane of a

Ultrafast laser beam shaping for material processing at imaging plane by geometric masks using a spatial light modulator

We have demonstrated an original ultrafast laser beam shaping technique for material processing using a spatial light modulator (SLM). Complicated and time-consuming diffraction far-field phase hologram calculations based on Fourier transformations are avoided, while simple and direct geometric masks are used to shape the incident beam at diffraction near-field. Various beam intensity shapes, such as square, triangle, ring and star, are obtained and then reconstructed at the imaging plane of an f-theta lens. The size of the shaped beam is approximately 20 µm, which is comparable to the beam waist at the focal plane. A polished stainless steel sample is machined by the shaped beam at the imaging plane. The shape of the ablation footprint well matches the beam shape

Optimization of process parameters for high efficiency laser forming of advanced high strength steels within metallurgical constraints

Laser forming (LF) has been shown to be a viable alternative to form automotive grade advanced high strength steels (AHSS). Due to their high strength, heat sensitivity and low conventional formability show early fractures, larger springback, batch-to-batch inconsistency and high tool wear. In this paper, optimisation of the LF process parameters has been conducted to further understand the impact of a surface heat treatment on DP1000. A FE numerical simulation has been developed to analyse the dynamic thermo-mechanical effects. This has been verified against empirical data. The goal of the optimisation has been to develop a usable process window for the LF of AHSS within strict metallurgical constraints. Results indicate it is possible to LF this material, however a complex relationship has been found between the generation and maintenance of hardness values in the heated zone. A laser surface hardening effect has been observed that could be beneficial to the efficiency of the process

Goal Driven Optimization of Process Parameters for Maximum Efficiency in Laser Bending of Advanced High Strength Steels

Abstract. Laser forming or bending is fast becoming an attractive option for the forming of advanced high strength steels (AHSS), due primarily to the reduced formability of AHSS when compared with conventional steels in traditional contact-based forming processes. An inherently iterative process, laser forming must be optimized for efficiency in order to compete with contact based forming processes; as such, a robust and accurate method of optimal process parameter prediction is required. In this paper, goal driven optimization is conducted, utilizing numerical simulations as the basis for the prediction of optimal process parameters for the laser bending of DP 1000 steel. A key consideration of the optimization process is the requirement for minimal microstructural transformation in automotive grade high strength steels such as DP 1000

Towards a rapid, non-contact shaping method for fibre metal laminates using a laser source

Abstract Since their initial development, fibre metal laminates (FMLs) have slowly started to be used by industry, particularly the aerospace sector. One of the reasons for the relatively slow adoption of FMLs is due to the difficulties faced in shaping them to the desired geometry. Whilst traditional processes such as roll forming are effective in shaping monolithic materials, these processes could potentially destroy the mechanical properties of the composite layer. The approached investigated here uses thermal or laser forming (LF) to shape flat panels of thermosetting glass fibre based FMLs into 2D geometries. This initial empirical investigation covers the effectiveness of the various LF processes and the effects of various parameters have on the forming process. These include laser parameters such as power and velocity and material parameters such as FML lay-up strategy, fibre orientation and comparison with monolithic materials

Experimental and numerical study of multi-pulse picosecond laser ablation on 316 L stainless steel.

An experimental and numerical study on 10 ps laser ablation of 316 L stainless steel up to 400 hundred pulse exposure has been carried out. In this simulation, the material removal threshold temperature has been carefully discussed depending on the different ablation driving mechanisms. The influence of the instantaneous material removal has also been considered which will affect the calculation of the next pulse's absorption. For single-pulse ablation, the simulated ablation threshold Fsim = 0.26 J/cm2 is close to the fitted experimental result F0th = (0.29 ± 0.01) J/cm2. For multi-pulse ablation, the simulated ablation rate Rsim = 11.4 nm/pulse is close to the fitted experimental result Rexp = (12.4 ± 0.1) nm/pulse under 0.9 J/cm2 fluence, while the simulated ablation rate Rsim = 19.8 nm/pulse is slightly larger than the fitted experimental result Rexp = (16.1 ± 0.7) nm/pulse at 2.7 J/cm2, providing good agreement between theory and experiment for both single and multi-pulse ablation. This study could be used to predict the multi-pulse laser processing performance, especially with the help of a machine learning method to find the best parameters automatically

Pulse Burst Generation and Diffraction with Spatial Light Modulators for Dynamic Ultrafast Laser Materials Processing.

A pulse burst optical system has been developed, able to alter an energetic, ultrafast 10 ps, 5 kHz output pulse train to 323 MHz intra-burst frequency at the fundamental 5 kHz repetition rate. An optical delay line consisting of a beam-splitting polariser cube, mirrors, and waveplates transforms a high-energy pulse into a pulse burst, circulating around the delay line. Interestingly, the reflected first pulse and subsequent pulses from the delay line have orthogonal linear polarisations. This fact allows independent modulation of these pulses using two-phase-only Spatial Light Modulators (SLM) when their directors are also aligned orthogonally. With hybrid Computer Generated Holograms (CGH) addressed to the SLMs, we demonstrate simultaneous multi-spot periodic surface micro-structuring on stainless steel with orthogonal linear polarisations and cylindrical vector (CV) beams with Radial and Azimuthal polarisations. Burst processing produces a major change in resulting surface texture due to plasma absorption on the nanosecond time scale; hence the ablation rates on stainless steel with pulse bursts are always lower than 5 kHz processing. By synchronising the scan motion and CGH application, we show simultaneous independent multi-beam real-time processing with pulse bursts having orthogonal linear polarisations. This novel technique extends the flexibility of parallel beam surface micro-structuring with adaptive optics