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Design and application of laser scanning strategy for machining deep surface grooves with a continuous-wave fiber laser

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Abstract

A laser scanning strategy for fabricating deep surface grooves using a continuous-wave fiber laser was investigated in this study. Because the low productivity of short-pulsed-wave lasers limits their application to a small scale, a continuous-wave (CW) fiber laser that can provide a high power density was used for the rapid fabrication of deep grooves. An innovative tailored laser scanning strategy of fabricating patterned deep grooves was analytically designed based on the power density and interaction time. Considering the thermophysical properties of the material, controlled laser processing parameters were determined for fabricating surface grooves with rectangular and chevron cross-sectional patterns. To confirm the usefulness of the research results, the scanning strategy obtained in this study was applied for achieving high-quality joining between injection-molded metal–plastic hybrids (MPHs). A deep-surface-grooved A5052 aluminum alloy sheet was bonded to two plastics, polyamide and polypropylene, via injection molding. Lap shear tensile tests of the MPHs revealed their significantly enhanced joining strength owing to a better mechanical interlocking of the groove. The developed laser scanning strategy using a CW fiber laser can be widely applied in the fabrication of deep grooves of various cross-sections with high reliability.

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Abbreviations

a :

Thermal diffusivity, m2s−1

A m :

Grooved cross-sectional area in the scanning direction, mm2

C p(l):

Specific heat capacity of a liquid phase at constant pressure, J/kg K

C p(s):

Specific heat capacity of a solid phase at constant pressure, J/kg K

E :

Power density, W/mm2

E a :

Absorbed power density from a laser source, W/mm2

E m :

Unit energy for the grooving, J/mm3

E n :

Net heat energy, J

dE n/dt :

Rate of heat energy delivered, J/s or W

E p :

Analytically required power density for grooving, W/mm2

L m :

Heat of fusion, kJ/kg

L v :

Heat of vaporization, kJ/kg

P :

Laser power, J/s or W

r B :

Beam radius, mm

T m :

Melting temperature, K

T o :

Room temperature, K

T p :

Peak temperature, K

T v :

Vaporization temperature, K

V :

Removed volume, mm3

v:

Laser beam moving rate, mm/s

dV/dt :

Removal volume rate, mm3/s

α:

Linear expansion coefficient, K−1

η :

Grooving efficiency

λ:

Thermal conductivity, Js−1m−1K−1

ρ:

Density, kg/m3

τ :

Beam interaction time, s

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Funding

This work was supported by a Korea Basic Science Institute (National Research Facilities and Equipment Center) grant, funded by the Ministry of Education. (Grant No. 2021R1A6C101A449).

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Authors and Affiliations

  1. School of Mechanical Engineering, Pusan National University, 30 Jangjeon-dong, Geumjeong-gu, Busan, 46241, Republic of Korea

    Si Qing Liu, Daniyal Abolhasani & Young Hoon Moon

  2. Research & Development Integrated Center, Hyundai-Steel, 1480, Bukbusaneop-ro, Songak-eup, Dangjin-si, Chungcheongnam-do, 31719, Republic of Korea

    Sang Wook Han

  3. Department of Joining Technology, Korea Institute of Materials Science, 797 Changwon-daero, Changwon, Gyeongnam, 51508, Republic of Korea

    Tae Woo Hwang

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Contributions

SQ Liu: investigation and writing—original draft. SW Han: investigation and methodology. TW Hwang: investigation and data curation. D Abolhasani: validation. YH Moon: supervision, project administration, and writing—review and editing. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Young Hoon Moon.

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Liu, S.Q., Han, S.W., Hwang, T.W. et al. Design and application of laser scanning strategy for machining deep surface grooves with a continuous-wave fiber laser. Int J Adv Manuf Technol 127, 4133–4147 (2023). https://doi.org/10.1007/s00170-023-11759-6

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