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Construction of a rapid simulation design tool for thermal responses to laser-induced feature patterns

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Abstract

There are many emerging manufacturing processes whereby surface structures are processed by spatially laser patterning of an entire feature at a time, as opposed to rastering a small beam. It is important to ascertain and ideally control the induced thermal fields underneath the pattern. This paper develops a computational framework to rapidly evaluate the induced thermal fields due to application of a laser on the surface. The aggregate thermal fields are efficiently computed by superposing individual “beamlet” heat-kernel solutions, based on Green’s functions, to form complex surface patterns. The utility of the approach is that laser-process designers can efficiently compute the results of selecting various system parameters, such as spatially-variable laser intensity within a pattern. This allows one to rapidly compute system parameter studies needed in the manufacturing of new products. Included are:

  • A computational framework to compute the time-transient thermal response from a spatio-temporally non-uniform laser beam in an arbitrary spatial pattern and

  • An analysis of how the results can be used to track the evolution of the thermal gradients and their correlation to thermal stresses.

Three-dimensional examples are provided to illustrate the technique. The utility of the approach is that an analyst can efficiently ascertain a large number of laser-input scenarios without resorting to computationally-intensive numerical procedures, such the Finite Element Method.

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Notes

  1. This is in contrast to (classical) “subtractive” processes which subtract material (for example using milling) to fabricate a component.

  2. The top is assumed insulated except where the load is present. See classical works of Jaeger [17] and Carslaw and Jaeger [2] for a complete, rigorous, derivation, and reviews in Kennedy [19] and Kachanov et al. [18]. The solution is obtaining by superposing a series of instantaneous thermal pulses and adding/integrating the solutions to represent a continuous source.

  3. In the idealized limit, the temperature would be constant.

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Acknowledgements

The author acknowledges generous support from Siemens Grant 85702-23845-44-EKZOH-EEZT85702X, under program manager Dr. Marco Brunelli.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of California, Berkeley, CA, 94720-1740, USA

    T. I. Zohdi

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Zohdi, T.I. Construction of a rapid simulation design tool for thermal responses to laser-induced feature patterns. Comput Mech 62, 393–409 (2018). https://doi.org/10.1007/s00466-017-1503-3

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  • DOI: https://doi.org/10.1007/s00466-017-1503-3

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