Cavity formation and surface modeling of laser milling process under a thin-flowing water layer

Abstract

Laser milling process normally involves a number of laser scans over a workpiece to selectively remove the material and then to form cavities with shape and dimensions required. However, this process adversely causes a heat accumulation in work material, which can in turn damage the laser-milled area and vicinity in terms of recast deposition and change of material properties. Laser milling process performing in a thin-flowing water layer is a promising method that can overcome such damage. With the use of this technique, water can flush away the cut debris and at the same time cool the workpiece during the ablation. To understand the potential of this technique for milling application, the effects of process parameters on cavity dimensions and surface roughness were experimentally examined in this study. Titanium sheet was used as a workpiece to be milled by a nanosecond pulse laser under different water flow velocities. A smooth and uniform cut feature can be obtained when the metal was ablated under the high laser pulse frequency and high water flow velocity. Furthermore, a surface model based on the energy balance was developed in this study to predict the cavity profile and surface roughness. By comparing to the experiments, the predicted profiles had a good agreement with the measured ones.