Laser thermal forming of sheet metal parts using desktop laser systems

Abstract

The bending of flat sheet metal materials using a laser process is not new to the metals industry. However, refining the process to the point where an angle bend can be predicted is significant when developing prototypes of small and large components. The methods and process developed to perform this task are presented, and key elements to maintain consistency and repeatability of the process are identified. A 50-Watt CO2 Desktop laser system provided the appropriate controls necessary to create the specific shapes. The forming tests were performed on CRES (302) with thickness varying from 0.26 mm to 0.64 mm. The variations of beam divergence, feed rate, laser power, and pulses per inch were evaluated, and the effects of these laser variables are presented. Material preparation techniques are also described since it was determined that the surface condition and the methods of edge preparation had significant effects on the overall results of forming. Compound radius bends were performed by calculating the effects of simple bends in conjunction with multiple passes. The data collected from the experiments were compiled and a section on the analysis of these data is also presented. This program was a joint effort in cooperation with the American Welding Society under contract with the Defense Advanced Research Projects Agency (DARPA). The initial development work was funded by DARPA through the Flexible Laser Automated Intelligent Research (FLAIR) program and the remaining work performed on the task was funded internally by High Tech Images and Tactical Technical Solutions, Inc. A synopsis of the laser forming process development and applications of the laser forming process are given.The bending of flat sheet metal materials using a laser process is not new to the metals industry. However, refining the process to the point where an angle bend can be predicted is significant when developing prototypes of small and large components. The methods and process developed to perform this task are presented, and key elements to maintain consistency and repeatability of the process are identified. A 50-Watt CO2 Desktop laser system provided the appropriate controls necessary to create the specific shapes. The forming tests were performed on CRES (302) with thickness varying from 0.26 mm to 0.64 mm. The variations of beam divergence, feed rate, laser power, and pulses per inch were evaluated, and the effects of these laser variables are presented. Material preparation techniques are also described since it was determined that the surface condition and the methods of edge preparation had significant effects on the overall results of forming. Compound radius bends were performed by calculating the...