Skip to main content

Advertisement

SpringerLink
Log in

Path calculation of 7-axes synchronous quasi-tangential laser manufacturing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

A Correction to this article was published on 09 May 2019

This article has been updated

Abstract

Quasi-tangential laser processing, also called laser turning, is increasingly applied for various applications. Specifically, its ability to generate complex geometries with small feature sizes at high precision and surface quality in hard, brittle, and electrically non-conductive materials is a key benefit. Due to the geometric flexibility, the process is well suited for prototyping in hard-to-machine materials such as ceramics, carbides, and super-abrasives. However, the lack of advanced software solutions for this novel process hitherto limited the exploitation of the potential. Here, we discuss a unique computer-aided manufacturing approach for synchronous 7-axes laser manufacturing with quasi-tangential strategies. This gives the peerless possibility to process arbitrary geometries, which cannot be manufactured with conventional techniques. A detailed description of the path calculation with derivation and procedures is given. The generated machine code is tested on a laser manufacturing setup consisting of five mechanical and two optical axes. Following, a processed cylindrical ceramic specimen with a continuously varying profile along a helical path is presented. The profile is constituted by a rectangular over half-spherical to a triangular groove with defined pitch on the helix. This demonstrator provides the validation of the presented CAM solution. Measurements of the produced specimen show high adherence with the target geometry and an average deviation below 10 μm.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Change history

  • 09 May 2019

    The original version of this article contained a mistake. The formulae and signs are not shown correctly in Fig. 5.

References

  1. Dubey AK, Yadava V (2008) Laser beam machining-a review. Int J Mach Tools Manuf 48(6):609. https://doi.org/10.1016/j.ijmachtools.2007.10.017

    Article  Google Scholar 

  2. Huang SH, Liu P, Mokasdar A, Hou L (2013) Additive manufacturing and its societal impact: a literature review. Int J Adv Manuf Technol 67(5-8):1191. https://doi.org/10.1007/s00170-012-4558-5

    Article  Google Scholar 

  3. Kulkarni P, Marsan A, Dutta D (2000) A review of process planning techniques in layered manufacturing. Rapid Prototyp J 6(1):18. https://doi.org/10.1108/13552540010309859

    Article  Google Scholar 

  4. Eberle G, Dold C, Wegener K (2015) Laser fabrication of diamond micro-cutting tool-related geometries using a high-numerical aperture micro-scanning system. Int J Adv Manuf Technol 81(5-8):1117. https://doi.org/10.1007/s00170-015-7240-x

    Article  Google Scholar 

  5. Gilbert D, Stoesslein M, Axinte D, Kell J, Mater J (2014) A time based method for predicting the workpiece surface micro-topography under pulsed laser ablation. Process Tech 214:3077. https://doi.org/10.1016/j.jmatprotec.2014.07.008

    Article  Google Scholar 

  6. Chen G, Deng H, Zhou X, Zhou C, He J, Cai S (2015) Online tangential laser profiling of coarse-grained bronze-bonded diamond wheels. Int J Adv Manuf Technol 79(9-12):1477. https://doi.org/10.1007/s00170-015-6963-z

    Article  Google Scholar 

  7. Tokarev VN, Wilson JIB, Jubber MG, John P, Milne DK (1995) Modeling of self-limiting laser-ablation of rough surfaces - application to the polishing of diamond films. Diam Relat Mater 4(3):169. https://doi.org/10.1016/0925-9635(94)00241-x

    Article  Google Scholar 

  8. Echlin MP, Titus MS, Straw M, Gumbsch P, Pollock TM (2017) Materials response to glancing incidence femtosecond laser ablation. Acta Mater 124:37. https://doi.org/10.1016/j.actamat.2016.10.055

    Article  Google Scholar 

  9. Kononenko VV, Kononenko TV, Pimenov SM, Sinyavskii MN, Konov VI, Dausinger F (2005) Effect of the pulse duration on graphitisation of diamond during laser ablation. Quantum Electron 35(3):252. https://doi.org/10.1070/QE2005v035n03ABEH002900

    Article  Google Scholar 

  10. Chong TC, Hong MH, Shi LP (2010) Laser precision engineering: from microfabrication to nanoprocessing. Laser Photonics Rev 4(1):123. https://doi.org/10.1002/lpor.200810057

    Article  Google Scholar 

  11. Malinauskas M, Žukauskas A, Hasegawa S, Hayasaki Y, Mizeikis V , Buividas R, Juodkazis S (2016) Ultrafast laser processing of materials: from science to industry. Light Sci Appl 5(8):e16133. https://doi.org/10.1038/lsa.2016.133

    Article  Google Scholar 

  12. Warhanek M, Pfaff J, Martin P, Schȯnbȧchler L, Boos J, Wegener K (2016) Geometry optimization of polycrystalline diamond tools for the milling of sintered Zro2. Procedia CIRP 46:290. https://doi.org/10.1016/j.procir.2016.04.003

    Article  Google Scholar 

  13. Warhanek M, Walter C, Hirschi M, Boos J, Bucourt JF, Wegener K (2016) Comparative analysis of tangentially laser-processed fluted polycrystalline diamond drilling tools. J Manuf Process 23:157. https://doi.org/10.1016/j.jmapro.2016.06.023

    Article  Google Scholar 

  14. Cheng X, Yang XH, Huang YM, Zheng GM, Li L (2014) Helical surface creation by wire electrical discharge machining for micro tools. Robot Comput Integr Manuf 30(3):287. https://doi.org/10.1016/j.rcim.2013.10.010

    Article  Google Scholar 

  15. Joneja A, Pang A, Lam D, Yuen M (2000) A CAD/ CAM system for vector-based layered manufacturing systems. Int J Comput Integr Manuf 13(5):388. https://doi.org/10.1080/09511920050117883

    Article  Google Scholar 

  16. Mutapcic E, Iovenitti P, Hayes JP (2006) A prototyping and microfabrication CAD/CAM tool for the excimer laser micromachining process. Int J Adv Manuf Technol 30(11-12):1076. https://doi.org/10.1007/s00170-005-0147-1

    Article  Google Scholar 

  17. Pothen M, Winands K, Klocke F (2017) Compensation of scanner based inertia for laser structuring processes. J Laser Appl 29(1):012017. https://doi.org/10.2351/1.4974906

    Article  Google Scholar 

  18. Fitzpatrick J, Leonard R (1993) The limits of programmed automation in a CAD/CAM/CNC precision engraving environment. Int J Comput Integr Manuf 6(3):201. https://doi.org/10.1080/09511929308944570

    Article  Google Scholar 

  19. Cerit E, Lazoglu I (2011) A CAM-based path generation method for rapid prototyping applications. Int J Adv Manuf Technol 56(1-4):319. https://doi.org/10.1007/s00170-011-3176-y

    Article  Google Scholar 

  20. Chee C, Kai J, Gan GK, Mei T (1997) Interface between cad and rapid prototyping systems. Part 1: a study of existing interface. Int J Adv Manuf Technol pp 566–570

  21. Chee C, Kai J, Gan GK, Mei T (1997) Interface between CAD and rapid prototyping systems. Part 2: LMI - an improved interface, Int J Adv Manuf Technol pp 571–576. https://doi.org/10.1007/BF01176300

  22. Stassen Boehlen I, Fieret J, Holmes AS, Lee KW (2003) Proc. SPIE, ed. by A Pique, K Sugioka, PR Herman, J Fieret, FG Bachmann, JJ Dubowski, W Hoving, K Washio, DB Geohegan, F Traeger, K Murakami, p 198. https://doi.org/10.1117/12.479533

  23. Wegener K, Heeling T, Zimmermann L (2016) Multi-beam strategies for the optimization of the selective laser melting process. Solid Free Fabr 2016 Proc. 27th Annu. Int. Solid Free. Fabr. Symp., pp 1428–1438. https://doi.org/10.3929/ETHZ-A-010803938

  24. (1988) Stereolithography interface specifications

  25. Gysel J (2017) CAM 2.5D laser ablation v2.0. https://doi.org/10.5281/zenodo.1048514. https://zenodo.org/record/1048515

  26. Mohan P, Pandey N, Venkata R, Dhande SG (2003) Slicing procedures in layered manufacturing: a review. Rapid Prototyp J 9(5):274. https://doi.org/10.1108/13552540310502185

    Article  Google Scholar 

  27. Aichholzer O, Aurenhammer F (1996) Straight skeletons for general polygonal figures in the plane. Comput Comb Lect Notes Comput Sci 1090:117–126. https://doi.org/10.1007/3-540-61332-3

    MathSciNet  MATH  Google Scholar 

  28. Felkel P, Obdrzalek S (1998) Proc. Spring Conf Comput. Graph., pp 210–218

  29. Held M, Palfrader P, Comput CAD (2017) Straight skeletons with additive and multiplicative weights and their application to the algorithmic generation of roofs and terrains. Aided Des 92:33. https://doi.org/10.1016/j.cad.2017.07.003

    Article  Google Scholar 

  30. Ackerl N, Warhanek M, Gysel J, Wegener K (2018) Ultrashort-pulsed laser machining of dental ceramic implants, J. Eur. Ceram. Soc. https://doi.org/10.1016/j.jeurceramsoc.2018.11.007

  31. Walter C (2014) Conditioning of hybrid bonded cbn tools with short and ultrashort pulsed lasers. Doctoral thesis, ETH Zurich

    Google Scholar 

Download references

Acknowledgments

Special thanks to Josquin Pfaff for steady help and discussion during the conception of the CAM toolbox. The opportunity to use the laser machining test bed at Dentalpoint AG is gratefully acknowledged.

Funding

The study was supported by the Swiss National Fund (FuSSiT/169654) and the Commission of Technology and Innovation (18474.1).

Author information

Authors and Affiliations

  1. Institute of Machine Tools and Manufacturing (IWF), ETH Zurich, Leonhardstrasse 21, 8092, Zurich, Switzerland

    Norbert Ackerl, Maximilian Warhanek, Johannes Gysel & Konrad Wegener

Authors
  1. Norbert Ackerl
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Maximilian Warhanek
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Johannes Gysel
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Konrad Wegener
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Norbert Ackerl.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

The original version of this article was revised: The formulae and signs are not shown correctly in Fig. 5.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ackerl, N., Warhanek, M., Gysel, J. et al. Path calculation of 7-axes synchronous quasi-tangential laser manufacturing. Int J Adv Manuf Technol 103, 1105–1116 (2019). https://doi.org/10.1007/s00170-019-03540-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-03540-5

Keywords

Search

Navigation