Numerical modeling of phase prediction and geometry evolution of micro-drilling using single pulse laser

Abstract

Due to high production capability, long laser pulses are preferred over ultrashort pulses during Laser-based machining. To reduce metallurgical defects, viz. heat-affected zone, recast layer, and micro-cracks, it is essential to analyze the causes of these defects and to derive the remedies. Generally, an extensive experimental investigation is carried out for the same. The experimental analysis is time-consuming, tedious, and requires high capital investment. Therefore, in this work, a two-dimensional axisymmetric transient finite element method (FEM) based numerical model of Laser-material interaction was developed to explore the temperature evolution, phase change, and geometry evolution with the help of coupled heat transfer and deformed mesh. The heat transfer module was implemented by considering the phase change using the apparent heat capacity method. The model was duly validated for the evolution and geometry of the Laser-drilled hole. The model was found in agreement with the experimental results, with a percentage deviation of 12% in the prediction of the responses. The numerical model will help to predict the temperate evolution and hydrodynamic behavior of the material during the laser-material interaction. This, in turn, will help to mitigate the metallurgical defects.