Laser cutting of holes in thick sheet metals: Development of stress field

Laser cutting of hole in a mild steel thick sheet metal is investigated. Temperature and stress fields developed around the cutting section are simulated using the finite element method. An experimental is carried out accommodating the simulation parameters. The residual stress developed in the cutting section is measured using the XRD technique and findings are compared with the predictions. Optical microscopy and SEM are carried out to examine the morphological changes in the cutting sections. It is found that temperature decays sharply in the region of the laser heat source, which results in high temperature gradient in this region. This causes the development of high stress levels around the cut edges. The residual stresses predicted are in agreement with the measured results.     

Laser cutting of thick sheet metals: Residual stress analysis

Laser cutting of tailored blanks from a thick mild steel sheet is considered. Temperature and stress field in the cutting sections are modeled using the finite element method. The residual stress developed in the cutting section is determined using the X-ray diffraction (XRD) technique and is compared with the predictions. The structural and morphological changes in the cut section are examined using the optical microscopy and scanning electron microscopy (SEM). It is found that temperature and von Mises stress increase sharply in the cutting section, particularly in the direction normal to the cutting direction. The residual stress remains high in the region close to the cutting section.     

Laser cutting of rectangular geometry into aluminum alloy: Effect of cut sizes on thermal stress field

Laser cutting of a rectangular geometry into aluminum alloy 2024 is carried out. Temperature and stress fields are predicted in the cutting section using the ABAQUS finite element code in line with the experimental conditions. Effect of the size of the rectangular geometry on the thermal stress fields is examined in the cutting section. Temperature predictions are validated through the thermocouple data. To identify the morphological changes in the cutting section, an experiment is carried out and the resulting cutting sections are examined under optical and scanning electron microscopes. It is found that temperature and stress fields are affected by the size of the rectangular cut geometry. Temperature and von Mises stress attains higher values for small size rectangular geometry as compared to its counterpart corresponding to the large size geometry. Laser cut sections are free from large size asperities including sideways burning and out-off flatness at the cut edges. Locally scattered some small dross attachments are observed at the kerf exit.     

Laser cutting of steel and thermal stress development

In laser cutting of sheet metals, thermal stresses are developed in the region of the cutting section. Depending on the cutting conditions and substrate material properties, the thermal stress levels can attain high values. In the present study, thermal stress developed in the region of the laser cut edges is modeled and temperature as well as stress fields are predicted. Temperature predictions are validated through the experimental results. It was found that the temporal variation of the maximum temperature along y-axis follows the laser heating source. However, temporal variation of von-Mises stress deviates slightly from the temporal variation of temperature along the cutting direction. Increase in scanning speed enhances the von-Mises stress levels due to the attainment of high temperature gradients in the substrate material.     

Laser cutting of sharp edge: Thermal stress analysis

Laser cutting of sharp edge and thermal stress development in the cutting section is examined. The finite element method is used to predict temperature and stress fields while the X-ray diffraction (XRD) technique is used to measure the residual stress around the cut edges. A mild steel sheet with 5 mm thickness is used in the simulations and the experiment. The morphological and metallurgical changes around the edges are examined using the optical microscopy and scanning electron microscopy (SEM). It is found that temperature remains high at the sharp edge when the laser beam is located in this region. This, in turn, lowers the cooling rate and reduces von Mises stress in this region. The magnitude of the residual stress is about 90 MPa at the sharp corner while the maximum von Mises stress is in the order of 280 MPa, which occurs away from sharp corner. In addition, the residual stress predicted agrees with the experimental data.     

Laser bending of AISI 304 steel sheets: Thermal stress analysis

Laser induced bending of steel sheet is carried out and thermal stress developed in the heated region is examined. Temperature and stress fields are predicted using the finite element model. The microstructural changes in the melted region are investigated through scanning electron microscope, energy dispersive spectroscopy and X-ray diffraction. The residual stress developed at the surface vicinity of the laser treated region is measured using the X-ray diffraction technique, which is then compared with its counterpart predicted from the simulations. It is found that the residual stress at the surface vicinity is compressive and the prediction of the residual stress agrees well with that obtained from the X-ray diffraction technique. In addition, surface temperature predictions are in good agreement with the thermocouple data. The laser treated region is free from major cracks and large cavities.     

Laser cutting of Kevlar laminates and thermal stress formed at cutting sections

Laser cutting of Kevlar laminates is carried out and thermal stress field developed in the cutting region is predicted using the finite element code. Temperature predictions are validated through the thermocouple data. The morphological changes in the cutting section are examined by incorporating optical and scanning electron microscopes. It is found that temperature predictions agree well with the thermocouple data. High values of von Mises stress are observed at the cutting edges and at the mid-thickness of the Kevlar laminate due to thermal compression formed in this region. The laser cut edges are free from whiskers; however, striation formation and some small sideways burning is observed at the kerf edges.     

Laser hole cutting into bronze: Thermal stress analysis

Laser hole cutting in bronze is carried out and the thermal stress formed in the cutting section is examined using a finite element code. The cut geometry and microstructural changes in the cutting section are examined using optical microscope, scanning electron microscope (SEM), and energy dispersive spectroscopy (EDS). It is found that the high conductivity of bronze increases the cooling rates within the cutting section, which influences the thermal stress field in the cutting region. The residual stress predicted is in the order of 200 MPa within the vicinity of the hole circumference. The striation pattern at the kerf surface changes towards the hole exit, which is associated with the drag forces developed in this region.     

Thermal and efficiency analysis of the CO2 laser cutting process

In CO₂ laser gas-assisted cutting process, modeling of the interaction mechanism is important. Consequently, the present study treats the complete problem of the interaction of the melting surface with the boundary layer and describes the behavior of the melting layer. In the analysis, gas–liquid interface parameters are developed and relationships between the parameters influencing the cutting action are identified theoretically. To achieve this, effects of momentum and gas–liquid interface shear stress, due to the assisting gas jet, are considered. The approximate magnitude of the heat absorbed is estimated and melting layer thickness is predicted. An experiment is carried out and the theoretical predictions are compared with the experimental findings. First and second law efficiencies of the cutting process are predicted, which may, then, be used to improve the process. It is found that the assisting jet velocity increases the first and second law efficiencies of the CO₂ laser cutting process.     

Effect of temperature on residual stress and mechanical properties of Ti films prepared by both ion implantation and ion beam assisted deposition

Ti films with a thickness of 1.6 μm (group A) and 4.6 μm (group B) were prepared on surface of silicon crystal by metal vapor vacuum arc (MEVVA) ion implantation combined with ion beam assisted deposition (IBAD). Different anneal temperatures ranging from 100 to 500 °C were used to investigate effect of temperature on residual stress and mechanical properties of the Ti films. X-ray diffraction (XRD) was used to measure residual stress of the Ti films. The morphology, depth profile, roughness, nanohardness, and modulus of the Ti films were measured by scanning electron microscopy (SEM), scanning Auger nanoprobe (SAN), atomic force microscopy (AFM), and nanoindentation, respectively. The experimental results suggest that residual stress was sensitive to film thickness and anneal temperature. The critical temperatures of the sample groups A and B that residual stress changed from compressive to tensile were 404 and 428 °C, respectively. The mean surface roughness and grain size of the annealed Ti films increased with increasing anneal temperature. The values of nanohardness and modulus of the Ti films reached their maximum values near the surface, then, reached corresponding values with increasing depth of the indentation. The mechanism of stress relaxation of the Ti films is discussed in terms of re-crystallization and difference of coefficient of thermal expansion between Ti film and Si substrate.     

Theoretical and experimental investigations on rotary ultrasonic surface micro-machining of brittle materials

Many brittle materials, such as single-crystal materials, amorphous materials, and ceramics, are widely used in many industries such as the energy industry, aerospace industry, and biomedical industry. In recent years, there is an increasing demand for high-precision micro-machining of these brittle materials to produce precision functional parts. Traditional ultra-precision micro-machining can lead to workpiece cracking, low machined surface quality, and reduced tool life. To reduce and further solve these problems, a new micro-machining process is needed. As one of the nontraditional machining processes, rotary ultrasonic machining is an effective method to reduce the issues generated by traditional machining processes of brittle materials. Therefore, rotary ultrasonic micro-machining (RUμM) is investigated to conduct the surface micro-machining of brittle materials. Due to the small diameter cutting tool (<500 μm) and high accuracy requirements, the impact of input parameters in the rotary ultrasonic surface micro-machining (RUSμM) process on tool deformation and cutting quality is extremely different from that in rotary ultrasonic surface machining (RUSM) with relatively large diameter cutting tool (∼10 mm). Up till now, there is still no investigation on the effects of ultrasonic vibration (UV) and input variables (such as tool rotation speed and depth of cut) on cutting force and machined surface quality in RUSμM of brittle materials. To fill this knowledge gap, rotary ultrasonic surface micro-machining of the silicon wafer (one of the most versatile brittle materials) was conducted in this study. The effects of ultrasonic vibration, tool rotation speed, and depth of cut on tool trajectory, material removal rate (MRR), cutting force, cutting surface quality, and residual stress were investigated. Results show that the ultrasonic vibration could reduce the cutting force, improve the cutting surface quality, and suppress the residual compressive stress, especially under conditions with high tool rotation speed.     

聚变实验堆真空室壳体成型残余应力分析

为了了解聚变实验堆真空室壳体表面残余应力的分布以及退火工艺对残余应力的影响，通过模拟分析和实验检测两种方式对不锈钢316LN冷压曲面和热压曲面残余应力进行研究，获得退火前后曲面表面残余应力的大小，得到冷压曲面和热压曲面残余应力的分布以及退火工艺对残余应力分布的影响。研究结果为分析成型工艺提供数据支撑，对中国聚变工程实验堆真空室的研究与制造具有重要意义。     

Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V

The titanium alloys cause high machining heat generation and consequent rapid wear of cutting tool edges during machining. The ultrasonic assisted turning (UAT) has been found to be very effective in machining of various materials; especially in the machining of “difficult-to-cut” material like Ti6Al4V. The present work is a comprehensive study involving 2D FE transient simulation of UAT in DEFORM framework and their experimental characterization. The simulation shows that UAT reduces the stress level on cutting tool during machining as compared to that of in continuous turning (CT) barring the penetration stage, wherein both tools are subjected to identical stress levels. There is a 40–45% reduction in cutting forces and about 48% reduction in cutting temperature in UAT over that of in CT. However, the reduction magnitude reduces with an increase in the cutting speed. The experimental analysis of UAT process shows that the surface roughness in UAT is lower than in CT, and the UATed surfaces have matte finish as against the glossy finish on the CTed surfaces. Microstructural observations of the chips and machined surfaces in both processes reveal that the intensity of thermal softening and shear band formation is reduced in UAT over that of in CT.     

Gamma-ray yields from 12C + 13C reactions near and below the coulomb barrier

The γ-ray yields from low-lying transitions in heavy residual nuclei produced in the ¹²C+¹³C reaction have been measured from E_c.m. = 3.1 to 11.9 MeV using a Ge(Li) detector. Total cross sections for compound nucleus formation were deduced from the experimental data with the aid of the Hauser-Feshbach model. Several independent checks on this procedure are described. These tests verify the assumptions made in the analyses of this reaction and suggest that the deduced cross sections have an absolute uncertainty of ±30 %. The present experimental results for the ¹²C+¹³C reaction are qualitatively very different from those for the ¹²C+¹²C reaction and do not provide any striking evidence for either broad singleparticle resonances in the total reaction cross section or for narrow non-statistical (quasimolecular) resonances in summed cross sections for proton and for α-particle emission to bound states of ²⁴Na and ²¹Ne, respectively. The predictions of several optical models employing attractive nuclear potentials are compared to the data. None is successful in reproducing the measured cross sections over the entire range of bombarding energy. The predictions at low energies depend sensitively on the shape of the potential a few fm inside the region of the nuclear surface. A narrow, rapidly varying energy dependence of the γ-ray yields is observed, with a peak-to-valley ratio of typically 1.1. However, a statistical analysis shows that these fluctuations, and those observed in recent charged particle measurements of α-particle yields, are reasonably consistent with those expected from the formation and decay of strongly overlapping levels in the compound nucleus. Finally, several observations are made on the validity of certain approximations often made in statistical analyses of heavy-ion reactions.     

Comparison of Cut Path Deviation Between CO2 and Diode Lasers in Float-Glass Cutting

Laser cutting of glass using the controlled fracture technique leads to cut path deviation at the leading and trailing edges of the float glass sheet. In this technique, thermal stresses are used to induce the crack, and the material is separated along the cutting path by extending the crack. We show that the cut path deviation is partly due to high magnitudes of thermal stresses generated near the sheet edges. The absorption of intense radiation from the CO₂ and diode laser beams in the glass causes local temperature increases and consequently generates different thermal fields and stress distributions due to surface and volumetric heat absorption. In this paper, we report the effect of the CO₂ and diode laser wavelength interaction with the float glass and its effect on the magnitudes of thermal stresses generated near the edges of the glass sheet. We simulate the distribution of the thermal stress and temperature using finite-element analysis software Abaqus and validate it against the experimental data. We show that the CO₂ laser produces a lower surface quality and a larger cut path deviation at the leading and trailing edges of the glass sheet as compared to the diode laser.     

Orientation dependent size effects in thermal buckling and post-buckling of nanoplates with cubic anisotropy

In this work, a continuum model is presented for size and orientation dependent thermal buckling and post-buckling of anisotropic nanoplates considering surface and bulk residual stresses. The model with von-Karman nonlinear strains and material cubic anisotropy of single crystals contains two parameters that reflect the orientation effects. Using Ritz method, closed form solutions are given for buckling temperature and post-buckling deflections. Regarding self-instability states of nanoplates and their recovering at higher temperatures, an experiment is discussed based on low pressurized membranes to verify the predictions. For simply supported nanoplates, the size effects are lowest when they are aligned in [100] direction. When the edges get clamped, the orientation dependence is ignorable and the behavior becomes symmetric about [510] axis. The surface residual stress makes drastic increase in buckling temperature of thinner nanoplates for which a minimum thickness is pointed to stay far from material softening at higher temperatures. Deflection of [100]-oriented buckled nanoplates is higher than [110] ones but this reverses at higher temperatures. The results for long nanoplates show that the buckling mode numbers are changed by orientation which is verified by FEM.     

The scattering of fast neutrons from W184

Neutrons with energies of 0.3 to 1.5 MeV are scattered from W¹⁸⁴. Pulsed-beam fast time-of-flight techniques including a magnetic bunching system are utilized to resolve the elastically scattered neutrons from those inelastically scattered. The differential elastic cross section is measured at 50 keV intervals with an ≈20 keV incident neutron energy spread. The differential cross sections for inelastic scattering resulting in the excitation of residual nuclear levels at 111±5, 365±10, 690±40, 900±25, 1000±30, and 1120±30 keV are determined. In all instances the inelastically scattered neutrons are emitted, within experimental error, isotropically. The experimental results are compared with those obtained in previous work and with the predictions of theory.     

High temperature thermal behaviour modeling of large-scale fused silica optics for laser facility

High temperature annealing is often used for the stress control of optical materials.However,weight and viscosity at high temperature may destroy the surface morphology,especially for the large-scale,thin and heavy optics used for large laser facilities.It is necessary to understand the thermal behaviour and design proper support systems for large-scale optics at high temperature.In this work,three support systems for fused silica optics are designed and simulated with the finite element method.After the analysis of the thermal behaviours of different support systems,some advantages and disadvantages can be revealed.The results show that the support with the optical surface vertical is optimal because both pollution and deformation of optics could be well controlled during annealing at high temperature.Annealing process of the optics irradiated by CO2 laser is also simulated.It can be concluded that high temperature annealing can effectively reduce the residual stress.However,the effects of annealing on surface morphology of the optics are complex.Annealing creep is closely related to the residual stress and strain distribution.In the region with large residual stress,the creep is too large and probably increases the deformation gradient which may affect the laser beam propagation.     

晶圆键合和激光剥离工艺对GaN基垂直结构发光二极管芯片残余应力的影响

GaN基发光二极管(LED)中的残余应力状态对器件的性能和稳定性有很大影响. 通过使用三种不同的键合衬底(Al₂O₃衬底, CuW衬底和Si衬底)以及改变键合温度(290 ℃, 320 ℃, 350 ℃和380 ℃), 并且使用不同的激光能量密度(875, 945和1015 mJ·cm^-2) 进行激光剥离, 制备了不同应力状态的GaN基LED器件. 对不同条件下GaN LED进行弯曲度、Raman 散射谱测试. 实验结果表明, 垂直结构LED中的残余应力的状态是键合衬底和键合金属共同作用的结果, 而键合温度影响着垂直结构LED中的残余应力的大小. 激光剥离过程中, 一定能量密度下激光剥离工艺一般不会对芯片中的残余应力造成影响, 但是如果该工艺对GaN 层造成了微裂缝, 则会在一定程度上起到释放残余应力的作用. 使用Si衬底键合后, 外延蓝宝石衬底翘曲变大, 对应制备的GaN基垂直结构 LED中的残余应力为张应力, 并且随着键合温度的上升而变大; 而Al₂O₃和CuW衬底制备的LED中的残余应力为压应力, 但使用Al₂O₃衬底键合制备的LED中压应力随键合温度上升而一定程度变大, CuW 衬底制备的LED中压应力随键合温度上升而下降.     

New thermoelastic technique for detection of residual stress distribution in solids

I.IntroductionNondestructiveeva1uationofstressdistributioninmaterialandmovingor1oadedcompo-nentsisveryimportantinmaterialscienccandengineering.Theultrasonictechnique['l,Ramanspectroscope['l,X-ray['landneutrondiffrac1iontcchnique[4]areusua1lyusedtodetectthestressdistributioninanopaquesample.RecentlytheScanningE1ectronAcousticMicroscopy(SEAM)[s]andphotoacoustictcchniquc[6]havebccnrcportedasncwtechniquetodeterminetheresidualstressdistribution.Itisshownthatthethermalwavealsocanbeusedtomcasure…