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Waterjet and laser etching: the nonlinear inverse problem.

A Bilbao-Guillerna1, D A Axinte1, J Billingham2

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Summary
This summary is machine-generated.

This study introduces a discrete adjoint algorithm to optimize material removal in waterjet and laser milling. The new method significantly reduces tracking error for complex freeform surface generation compared to traditional approaches.

Keywords:
adjoint optimizationinverse problempulsed laser ablationwaterjet milling

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Computational Engineering

Background:

  • Waterjet milling (WJM) and pulsed laser ablation (PLA) are layer-by-layer material removal processes for creating complex shapes.
  • The inverse problem in these processes involves determining the tool path for a desired surface geometry.
  • Existing methods often fail for complex surfaces due to neglecting beam footprint and overlap effects.

Purpose of the Study:

  • To develop an improved method for solving the inverse problem in WJM and PLA.
  • To enhance the accuracy of freeform surface generation by accounting for nonlinear material removal and beam overlap.
  • To reduce tracking error in depth-controlled material removal processes.

Main Methods:

  • A discrete adjoint algorithm is proposed to optimize the 2D beam path for material removal.
  • The algorithm incorporates nonlinear material removal models and non-straight tool paths.
  • Jacobian matrix calculations are optimized for computational efficiency.

Main Results:

  • The discrete adjoint algorithm reduces tracking error by approximately a factor of two compared to pixel-by-pixel and raster path methods.
  • Achieved tracking errors are as low as 2-5% for WJM and 1-2% for PLA.
  • The method effectively handles nonlinear effects and complex surface geometries.

Conclusions:

  • The proposed discrete adjoint algorithm offers a significant improvement for controlling material removal in WJM and PLA.
  • This advanced approach enables more accurate fabrication of freeform surfaces.
  • The method provides a computationally efficient and accurate solution for complex manufacturing challenges.