Kerf Geometry Research Articles

Laser cutting using dynamically modulated intensity distribution

The precise control of the laser beam intensity distribution facilitates the optimization of laser processing performance. This not only presents opportunities for enhancing the process efficiency but also proves advantageous in scenarios where the same laser power level is employed, surpassing traditional methods. This study introduces a novel approach by dynamically modulating the laser beam profile to achieve a non-symmetrical intensity distribution. A detailed investigation into the laser cutting process using modulated beam intensities is conducted by employing a high-speed imaging system. Moreover, the maximum cutting speed, cut edge quality, and cut kerf geometries are evaluated when different strategies are applied. The results demonstrate a noticeable improvement in the cut edge quality compared to a static beam strategy (SBS) and the recently developed conventional dynamic beam shaping (DBS). In addition to laser cutting, examples of such modulation in laser welding and hardening are proposed. This innovative technique offers promising advancements in the field of laser processing.

Experimental investigation of plasma arc cutting process to evaluate the characteristics of kerf geometry using ANOVA

Experimental investigation of plasma arc cutting process to evaluate the characteristics of kerf geometry using ANOVA

Characterization and process optimization of remote laser cutting of current collectors for battery electrode production

Aluminum (Al) and copper (Cu) metal foils of thickness 6–20 µm are employed as current collectors for the production of Li-ion battery cathodes and anodes. Greater demand for this product is driving up production rate requirements, especially in the field of car manufacturing. Laser-based cutting processes for trimming and cutting electrodes are considered suitable for meeting this demand as they can achieve very high throughput while maintaining process quality. In order to meet market requirements, laser manufacturers are developing new laser sources, optics, and scanning heads that will improve process productivity and quality. Establishing the relationship between the laser system and cut quality will lead to competitiveness, increased productivity, and sustainability production. This paper presents a thorough analysis of the cutting performance of pulsed and continuous-wave lasers with scanning speeds of up to 28 m/s for processing thin Al and Cu current collectors. Comparisons between process outcomes are made in terms of maximum and minimum cutting speed and power, kerf geometry, cut quality, and presence of defects. Identification of configurations leading to high and low cut quality enables detailed process parameter windows to be defined for both laser system systems employing continuous-wave and pulsed sources. By analyzing correlations between the materials, laser source, and process variables, the main outcome is that continuous-wave single-mode fiber lasers enable highest cut quality in the high-productivity regime, surpassing the current state-of-the-art in laser cutting of metal foils.

Finite Element Simulation and Experimental Assessment of Laser Cutting Unidirectional CFRP at Cutting Angles of 45° and 90°.

Laser cutting of carbon fibre-reinforced plastics (CFRP) is a promising alternative to traditional manufacturing methods due to its non-contact nature and high automation potential. To establish the process for an industrial application, it is necessary to predict the temperature fields arising as a result of the laser energy input. Elevated temperatures during the cutting process can lead to damage in the composite's matrix material, resulting in local changes in the structural properties and reduced material strength. To address this, a three-dimensional finite element model is developed to predict the temporal and spatial temperature evolution during laser cutting. Experimental values are compared with simulated temperatures, and the cutting kerf geometry is examined. Experiments are conducted at 45° and 90° cutting angles relative to the main fibre orientation using a 1.1 mm thick epoxy-based laminate. The simulation accurately captures the overall temperature field expansion caused by multiple laser beam passes over the workpiece. The influence of fibre orientation is evident, with deviations in specific temperature data indicating differences between the estimated and real material properties. The model tends to overestimate the ablation rate in the kerf geometry, attributed to mesh resolution limitations. Within the parameters investigated, hardly any expansion of a heat affected zone (HAZ) is visible, which is confirmed by the simulation results.

Laser cutting of basalt fibre reinforced polymers by QCW fiber laser: Interaction mechanisms and effect of laser parameters

In the paper, laser cutting of basalt fibre reinforced polymer laminate using a 450 W QCW fiber laser, working in a pulsed regime is presented. Preliminary tests were performed on a basalt laminate, 1.3 mm in thickness, changing the pulse power (Pp) and pulse duration (D) to find the maximum cutting speed. Then a 33 experimental plan was carried out changing the pulse power, the pulse duration, and the cutting speed. The kerf width and the heat-affected zone were measured in the section and on the external surfaces. ANOVA analysis was adopted to assess the process parameters’ influence. The interaction mechanisms were found and discussed. From the results, the BFRP laminate appears easy to cut at maximum cutting speeds up to 3500 mm/min. However, thermal damages occur. Kerf geometry and HAZ are mainly affected by the cutting speed, while the Pp and D seem to have a minor role.

Modelling the cross-sectional profile of the kerf generated in overlapped pass erosion in abrasive waterjet milling of Al6061-T6 alloy

Machining complex surfaces on difficult-to-cut materials by conventional methods is challenging due to the issues that arise from both the ‘freeform surface generation’ and the ‘machining difficult-to-cut materials’. On the other hand, abrasive waterjets (AWJs) have proven their unique capabilities in machining a wide range of materials and 3D shapes by maneuvering the jet strategically. In realizing 3D shapes through AWJ milling, the cross-sectional profile (CP) of the kerf, i.e. (i) trench — formed in a single pass erosion and (ii) cavity — formed in an overlapped pass erosion, need to be predicted apriori. However, the stochastic and aggressive behaviour of the AWJ, and the lack of complete understanding of the kerf generation, make the accurate prediction of its CP a difficult task. Furthermore, the cavity generated (by overlapping two trenches) is not a simple linear combination of trenches generated in two single AWJ passes. Also, the modelling efforts that consider both the dynamic jet characteristics and the non-linearity in the kerf formation are very limited. In this work, analytical models are proposed to predict CP the kerf (trench and the cavity) milled by the AWJs by considering the experimental understanding gained on the kerf generation in single and overlapped pass erosion. The modelling strategy evaluates the local erosion volume and sweeps this over the CP along the top width of the kerf. This strategy enables the incorporation of region-wise physical phenomenon in the material removal. Furthermore, it considers the (i) aggressive and stochastic nature of the AWJ, and (ii) particle erosion theories applicable to ductile materials, which pose multiple challenges during conventional machining. The model developed for the trench considers the effective jet divergence, spatial abrasive mass- and velocity-distributions in the jet plume, as inputs. Towards capturing the non-linearity in the cavity generation, the non-flat surface from the previous pass and its effect on the variation of local particle impact angles, uneven jet deflection during subsequent passes around the jet axis, and the degree of overlap were considered. From the experimental validation, it was observed that in the single pass and overlapped passes at different degrees of overlaps (5 %–80 %), the proposed model predicts the kerf geometry with a maximum mean absolute error (MAE) of 36 μm and 49 μm, and the maximum depth of CP with a maximum error of 7 % and 11 %, respectively.

Integration of CFD simulated abrasive waterjet flow dynamics with the material removal model for kerf geometry prediction in overlapped erosion on Ti-6Al-4V alloy

Complex surfaces in difficult-to-machine materials can be milled by maneuvering the abrasive waterjet (AWJ) according to the local part geometry by suitably overlapping the kerf cross-sectional profiles (CPs). The CP of a kerf milled in a single pass (i.e., trench) and overlapped pass (i.e., cavity) erosion by the AWJ are the building blocks that need to be known apriori for developing a jet path strategy to achieve a complex surface. This demands an efficient model for the kerf CP prediction. The present work proposes a novel framework for overlapped kerf CP prediction, wherein the jet characteristics of the AWJ exiting the focusing tube are evaluated from the two-phase flow computational fluid dynamics simulation coupled with the material removal model developed based on energy conservation principles. Towards incorporating the non-linearities observed in the kerf formation from the overlapped experimental trials into the model for CP prediction enhancement, the following are considered: (i) a hypothesis: ‘secondary erosion by the jet on the previously eroded kerf increases material removal’, (ii) the varying jet-material property of the ductile material (Ti-6Al-4V alloy), and (iii) local particle impact angles. Furthermore, the variation in the above mentioned non-linearities is incorporated into the model under the change in the AWJ conditions. From the results, it is observed that the proposed models predicted (i) the trench CP with a mean absolute error (MAE) of 27 μm, and the maximum erosion depth (hmax) with an error < 2%, and (ii) cavity at different overlaps (7% – 82%) and jet traverse rate (3000 mm/min – 5000 mm/min) with a MAE of 47 μm, and the hmax with an error < 6%. The predicted geometry of the CP correlates well with the experimental ones, with an average R2 of 0.98 and 0.95 in single- and overlapped- pass erosions.

Kerf Geometry and Surface Roughness Optimization in CO2 Laser Processing of FFF Plates Utilizing Neural Networks and Genetic Algorithms Approaches

This work deals with the experimental investigation and multi-objective optimization of mean kerf angle (A) and mean surface roughness (Ra) in laser cutting (LC) fused filament fabrication (FFF) 3D-printed (3DP), 4 mm-thick polylactic acid (PLA) plates by considering laser feed (F) and power (P) as the independent control parameters. A CO2 laser apparatus was employed to conduct machining experiments on 27 rectangular workpieces. An experimental design approach was adopted to establish the runs according to full-combinatorial design with three repetitions, resulting in 27 independent experiments. A customized response surface experiment was formulated to proceed with regression equations to predict the responses and examine the solution domain continuously. After examining the impact of F and P on mean A and mean Ra, two reliable prediction models were generated to model the process. Furthermore, since LC is a highly intricate, non-conventional machining process and its control variables affect the responses in a nonlinear manner, A and Ra were also predicted using an artificial neural network (NN), while its resulting performance was compared to the predictive regression models. Finally, the regression models served as objective functions for optimizing the responses with an intelligent algorithm adopted from the literature.

Gaussian distribution-based modeling of cutting depth predictions of kerf profiles for ductile materials machined by abrasive waterjet

This study proposes a model for the erosion cutting profile to predict the cutting depth under different process parameters for abrasive waterjet (AWJ) cutting. The model follows the Gaussian distribution and is experimentally validated. Additionally, the effects of the dimensional characteristics and process parameters on the kerf geometry were analyzed. It was found that the water pressure, abrasive flow rate, and focusing tube traverse speed changed the slope of the kerf wall without changing the kerf width. However, the standoff distance (SOD) changes the kerf width, whereas the slope of the kerf wall induces minor changes. Furthermore, based on the first-order derivation of the extracted kerf profile, the relationship between jet energy, cutting depth, and kerf width was analyzed. The experimental results revealed that: 1) the relationship between the reduction in the jet energy distribution and cutting depth is non-linear; 2) the jet energy distribution is smallest at the kerf top edge and bottom section. The predictive cutting depth model and jet energy distribution will enable the subsequent optimization of process parameters in the AWJ process.

An experimental study of abrasive waterjet deep hole drilling on Inconel 718

Inconel 718 is the most dominant alloy to manufacture 50% of aerospace components due to its excellent oxidation resistance, and good corrosion and erosion resistance across a wide range of temperatures. These aerospace components require small and micro-holes with high aspect ratios for specific functions. Among all the modern manufacturing processes, Abrasive Waterjet Machining (AWJM) is gaining popularity to produce such holes with its superior potential to machine all kinds of materials in the absence of heat and with minimum damage to the work surfaces. This research work attempted to study the output responses, namely material removal rate, kerf geometry, and surface roughness viz constant water pressure, varied Stand-Off Distance (SOD), and Abrasive Mass Flow Rate (AMFR). This research reveals that AWJM has excellent potential to make deep holes on Inconel 718 with the following outcomes; the material removal rate has been increased with increased mass flow rate and the kerf angle and surface roughness of the drilled holes have been decreased with the increased mass flow rate.

Modeling of abrasive waterjet generated kerf on the top layer of a multi-layered structure

Abrasive waterjet (AWJ) is an effective tool for manufacturing parts from multi-layered structures (MLSs) due to its capability in machining a wide range of materials. However, the challenge in employing AWJ in producing the desired kerf geometry in MLS can be attributed to the complex nature of the jet's interaction with multiple layers that possess different material properties. Hence, a model that captures the interaction of the jet with MLS, and predicts the whole kerf geometry is required to gain control over the kerf quality. On the other hand, the kerf generated in a layer is affected by the presence of preceding-/following- layers. In this context, it is essential to develop a comprehensive model for the prediction of kerf profile during the penetration of the jet in each layer. Although, several models exist to predict the process response (erosion depth, top ( w t ), and bottom kerf width ( w b ), kerf taper), very limited models available on kerf profile prediction. Further, neglecting the actual jet characteristics limits their ability to predict accurately. By considering the above, this work proposes a model for the prediction of the kerf geometry (profile and characteristics) in a single layer of MLS along with its kerf characteristics apart from considering the non-linearities, such as jet characteristics and the effects of AWJ process parameters . A discretized form of the jet, abrasives mass flow distribution, and their velocity in the jet plume to realize a more realistic model for predicting kerf geometry. Further, a new parameter, ' depth of damaged region ’ was defined towards realizing the w t . The model was evaluated by comparing the kerf geometry formed on mild steel (MS) and aluminum (Al) materials by using root mean square and mean absolute error. The proposed model was found to predict the kerf geometry accurately. • First model to predict AWJ generated kerf profile considering abrasive particle velocity profile and mass flow rate distribution. • Development of analytical model to accurately predict the complete kerf profile in a single layer cut by AWJs. • Erosion theories combined with discretization approach in the development of model. • Effective representation of the top kerf width in different materials based on depth of damaged region.

Surface morphology and defect characterization during high-power fiber laser cutting of SiC particles reinforced aluminum metal matrix composite

Due to the introduction of ceramic reinforcement, the physical properties and machinability of SiCp/Al composites are greatly different from the metallic ones. High-power continuous wave fiber laser makes it possible to process SiCp/Al composites with high efficiency. In this work, the feasibility of high-power fiber laser cutting of 5.0 mm thick SiCp/Al composites was studied using design of experiments (DOE). The effects of laser power (1000–4000 W), cutting speed (500–2000 mm/min) and assist gas (N2 and O2) on kerf geometry and defect characterization were investigated. Results showed that high laser power and low cutting speed generated relatively higher kerf width on the entry surface, and the kerf width exhibited a slightly higher level around ∼ 2.0% when O2 was applied in comparison to the results from N2 group. Different morphology was observed on machined surfaces including multi-directional striation, vertical striation and slant striation. The width of HAZ increased along the direction of laser beam, and reached the maximum value at egress with the value up to 1115 μm. The SEM and EDX spectra study showed that the effect of oxygen on the subsurface was limited, and there was no metallurgical reaction between the matrix and SiC particles during laser cutting process.

A feasibility study on high-efficient laser cutting of SiC particles reinforced aluminum matrix composite using single-pass strategy

Conventional machining of particles reinforced metal matrix composite (PRMMC) is very challenging due to the uniform distribution of abrasive reinforced SiC particles, which easily causes machined surface scratches and severe tool wear. The rapid development of high-power fiber laser has made it possible to cut PRMMCs with high efficiency. In this work, high-power fiber laser was employed to cut 5.0 mm thick SiC particle reinforced aluminum (SiCp/Al) composites. The effects of laser power, cutting speed and assist gas pressure on surface morphology and defect characteristics were investigated. The statistical analysis was conducted to investigate interaction between cutting parameters and kerf geometry. A high-resolution confocal laser scanning microscope was used to further analyze machined surface morphology and microscopic defects. Thermal defects were highly related to cutting parameters, which included cataphracted dross, droplet dross, craters, apophyses, microcracks and combustion. Microcracks were prevalent mainly due to the difference in thermal properties between reinforcement and matrix materials. Three dimensional finite element simulation of two-phase SiCp/Al composites was carried out to predict the temperature and stress distribution, and the striation formation mechanisms were further explained. A new method for predicting thermal stress of SiCp/Al composites was proposed and subsequently compared/validated with experimental results.

Experimental analysis on waterjet-guided Nd: YAG laser thin wood machining

Waterjet-Guided Laser (WJGL) machining is an advanced technique providing efficiency and precision for wood machining. The present study investigates the practical demonstration and analysis of laminated object manufacturing (LOM) WJGL for thin wood machining. A theoretical process of wood laser cutting was established, expressing relations between the cut kerf width and the influencing parameters. WJG Nd: YAG laser system was utilized for machining Korean pine and Northeast China ash specimen of 3 mm thickness, each with 7.21 and 7.13% of water content, respectively, under different machining conditions. The effects of process parameters and influences on woodcut surface geometry were analyzed via analysis of variance (ANOVA) and scanning electron microscopy (SEM). The investigated parameters include the laser cutting speed, power, kerf width, heat-affected zone (HAZ), and cut surface roughness. The study shows that the kerf width and surface were significantly influenced by WJGL power, followed by the cutting speed. For both wood specimens, at a fixed laser cutting speed of 2.36 mm/s, the kerf width increases significantly with laser power, affecting the cut surface quality accordingly. At 6 W and 8 W, the cut kerf geometry and surface quality were excellent for the Pinus Koraiensis, with kerf widths of 0.79 and 0.852 mm, respectively. At a fixed laser power of 8 W, the kerf width decreases with the cutting speed, affecting the cut surface quality. At a cutting speed of 4.33 mm/s, an excellent cut surface of Fraxinus mandshurica was observed with 0.808 mm of kerf width. Depending on the machining conditions, the kerf width variations of Korean pine were more significant than the Northeast China ash. LOM-WJGL is an efficient and eco-friendly technique for thin wood processing.Graphical abstractArticle HighlightsPractical modeling demonstration of waterjet guided laser (WJGL) wood machining.Experimental investigation of different wood specimens under influenced process parameters and machining conditions.Characterization and identification of suitable wood types for efficient and eco-friendly applications.

Interaction mechanisms and damage formation in laser cutting of CFRP laminates obtained by recycled carbon fibre

The increase in the use of composite materials poses the problem of their disposal/recycling after the End of Life (EOL). Different strategies were developed to recycle composite material, resulting in the availability of new raw materials, characterised by overall good mechanical properties and significantly low cost. However, the applicability of these materials to industrial production also depends on the possibility of producing and processing them with likewise available technologies. Among the production and processing technologies that can be adopted for recycled composite materials, resin infusion under flexible tooling (RIFT) and laser machining, respectively, stand out above all due to the high production/machining speed compared to the cost. This paper investigates the possibility to apply both these technologies to carbon fibre–reinforced polymer laminates obtained by adopting recycled carbon fibres. Recycled CFRP plates of about 2.7 mm in thickness were produced by RIFT and characterised in tensile and flexural tests. After mechanical characterisation, cutting tests were performed by using a 450 W QCW fibre laser, varying the pulse power, the pulse length, and the pulse overlap. The kerf geometries and the HAZ extension were measured at the upper and bottom parts as well as in the section. Analysis of variance was adopted to define which and how the process parameters affect the kerf dimension and HAZ extension. Results showed that it is possible to cut the composite at a cutting speed up to 2000 mm/s, obtaining, in the best conditions, narrow kerf, limited HAZ, and taper angle of about 0°.Graphical abstract

Application of a Robust Decision-Making Rule for Comprehensive Assessment of Laser Cutting Conditions and Performance

Laser cutting parameters synergistically affect, although in different quantitative and qualitative manners, multiple process performances, such as the resulting cut quality characteristics, material removal rate, cutting time, and costs, and the determination of the most appropriate laser cutting conditions for a given application is of prime importance. Given the existence of multiple mutually opposite performances, assessment and laser cutting conditions and performance can be considered a multiple-criteria decision-making (MCDM) problem. In order to overcome the possible inconsistency of rankings determined by different MCDM methods while solving the same decision-making problem, the present study promotes a novel methodology for the assessment and selection of laser cutting conditions by developing a robust decision-making rule (RDMR) that combines different decision-making rules from six MCDM methods and Taguchi’s principles of robust design. In order to illustrate the application of the proposed methodology, CO2 laser cutting in a stainless-steel experiment, based on the use of the Box–Behnken design, was conducted. On the basis of the experimental results, a comprehensive laser cutting MCDM model was developed with seven criteria related to cut quality (i.e., kerf geometry and cut surface), productivity, variable costs, and environmental aspects. It was observed that there was no laser cutting condition that could be considered as the best regime with respect to the different laser cutting process performances. Kendall’s and Spearman’s rank correlation coefficients indicated a certain level of disagreement among the resulting rankings of the laser cutting conditions produced by the considered MCDM methods, whereas the application of the proposed RDMR ensured the highest level of ranking consistency. Some possibilities for modeling of RDMR and its further use for the assessment of arbitrarily chosen laser cutting conditions and the use of the derived model to perform sensitivity analysis for determining the most influential laser cutting parameters are also discussed and addressed. It was observed that laser cutting parameters in different laser cutting conditions may have a variable effect on the resulting overall process performances. The comparison of the obtained results and the results determined by classical desirability-based multi-objective optimization revealed that there exists substantial agreement between the most preferable and least preferable laser cutting conditions, thus justifying the applied methodology.

Surface characteristics investigation of 3D-printed PET-G plates during CO2 laser cutting

ABSTRACT This study investigates the influence of the stand-off distance (SoD), laser speed (LS) and laser power (LP) on kerf geometry (upper width Wu, down width Wd and kerf angle KA) and mean surface roughness (Ra) during CO2 laser cutting of 3D-Printed Polyethylene-Terephthalate-Glycol (PET-G) thin plates. A full factorial design is implemented, having two levels for SoD and three levels for LS and four levels for LP, resulting in twenty-four (24) cuts. The specimens were manufactured with the Fused Filament Fabrication (FFF) process and had a thickness of 4 mm. First, the Wu, Wd, and KA parameters were measured. Then, the specimens were cut into 24 smaller parts, and the Ra of the processed surfaces was measured. After analyzing the results using descriptive statistical analysis and contour plots corresponding to the two objectives of KA and Ra, a feed-forward and backpropagation neural network (FFBP-NN) was applied. After a series of subsequent training, it was found that the 3-10-2 NN architecture was quite efficient in explaining the variation in terms of the responses, thus having merit in practical applications related to laser cutting. The LC surfaces showed much better Ra (7.2-12 μm) than those in the literature for FFF parts surfaces without post-processing (10.3-30 μm).

Modelling of abrasive waterjet kerf in a double-layered structure

Abrasive waterjets can process multi-layered structures but pose difficulties in producing quality cuts since MLS comprises of layers of materials with heterogeneous/homogenous properties. Stacking sequence of layers and the interface between layers influence kerf characteristics. Kerf geometry in each layer is influenced by a nonlinear structure with non-uniform energy distribution of AWJ. This paper presents a model to predict kerf geometry in a double-layered structure by considering jet characteristics, workpiece properties, jet-workpiece interaction at the layers' interface, and AWJ process parameters. Towards determining the jet's exclusive interaction with each layer, complete kerf profile (CKP) formation is analyzed by considering homogenous materials as constituent layers of Al-MS and MS-Al configurations. The model predicted results are in good agreement with experimental results. The average root mean square error of the kerf profile is less than 0.048 mm, and the mean absolute error is about 12.63% on both configurations. • First attempt to model the kerf cross-sectional profile in double-layered-structures (DLS) with abrasive waterjets (AWJs) • Discretization approach for prediction of the comprehensive kerf cross-sectional profile (CKP) in DLS cut by the AWJs • Prediction of the CKP in DLS considering AWJ process parameters, jet characteristics and workpiece properties • Non-linearity in kerf width at the interface of layers in DLS attributed to jet-workpiece interaction at the interface

A Generalised Approach on Kerf Geometry Prediction during CO2 Laser cut of PMMA Thin Plates using Neural Networks

This study presents an application of feedforward and backpropagation neural network (FFBP-NN) for predicting the kerf characteristics, i.e. the kerf width in three different distances from the surface (upper, middle and down) and kerf angle during laser cutting of 4 mm PMMA (polymethyl methacrylate) thin plates. Stand-off distance (SoD: 7, 8 and 9 mm), cutting speed (CS: 8, 13 and 18 mm/sec) and laser power (LP: 82.5, 90 and 97.5 W) are the studied parameters for low power CO2 laser cutting. A three-parameter three-level full factorial array has been used, and twenty-seven (33) cuts are performed. Subsequently, the upper, middle and down kerf widths (Wu, Wm and Wd) and the kerf angle (KA) were measured and analysed through ANOM (analysis of means), ANOVA (analysis of variances) and interaction plots. The statistical analysis highlighted that linear modelling is insufficient for the precise prediction of kerf characteristics. An FFBP-NN was developed, trained, validated and generalised for the accurate prediction of the kerf geometry. The FFBP-NN achieved an R-all value of 0.98, in contrast to the ANOVA linear models, which achieved Rsq values of about 0.86. According to the ANOM plots, the parameter values which optimize the KA resulting in positive values close to zero degrees were the 7 mm SoD, 8 mm/s CS and 97.5 W LP.

Absorption of tailored laser beams within 3D laser cutting kerfs

Detailed knowledge about the laser-material interaction, especially the distribution of laser power absorption, is a prerequisite for the simulation and optimization of laser material processing. In this work, an algorithm based on ray tracing is presented to calculate the propagation and the absorption of a laser beam inside a complex 3D cutting kerf. To model the laser beam precisely, a ray source based on high-power intensity measurements of the laser beam emitted from a highly multimode step-index fiber is set up. For the 3D reconstruction of the cutting kerf geometry, a semicircle model derived from three characteristic lines of so-called “frozen cuts” is applied. The presented approach enables a direct simulation of the laser absorption inside the cutting kerf considering light propagation properties like beam degeneration, shadowing effects, and multiple reflections. As a benchmark, it is finally applied to analyze cutting experiments in stainless steel with an axicon telescope.