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Controlled Continuous Patterning of Spherical Stainless Steel by Multi-Axis Linkage Laser Milling.

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  • 1Center for Precision Engineering, Harbin Institute of Technology, Harbin 150001, China.

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Summary

This study presents a novel multi-axis laser milling technique for precise, continuous surface texturing on curved, miniature stainless steel parts. The method ensures high uniformity and accuracy for non-planar surfaces, overcoming previous limitations in laser ablation.

Keywords:
laser surface texturingmulti-axis millingnon-planar patterningposturetool path

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Technology
  • Precision Engineering

Background:

  • Laser surface texturing is effective for planar microstructures but faces challenges with non-planar surfaces on miniature parts.
  • Achieving micrometer accuracy in continuous patterning on high-curvature surfaces via laser ablation remains a significant hurdle.
  • Existing methods struggle with uniformity and precision for complex geometries in laser surface texturing.

Purpose of the Study:

  • To demonstrate the feasibility of multi-axis laser milling for continuous patterning on non-planar surfaces.
  • To develop a method for high-uniformity and high-precision laser surface texturing of miniature spherical parts.
  • To enable continuous patterning of complex microstructures on large-curvature surfaces using laser ablation.

Main Methods:

  • A miniaturized five-axis platform was integrated with a nanosecond pulsed laser (1064 nm) for workpiece motion control.
  • A strategy was employed to simultaneously adjust the laser-surface interaction point's position and posture.
  • Precise laser-surface interaction paths were derived using pattern projection and transformation onto the spherical surface.
  • A virtual prototype with an embedded interpolation algorithm generated numerical control (NC) codes for laser milling.
  • Laser processing parameters were specifically sampled and optimized for spherical surface texturing.

Main Results:

  • Continuous patterning of complex microstructures was successfully achieved on 25 mm diameter spherical stainless steel.
  • The multi-axis laser milling method demonstrated long-range uniformity and local high accuracy of fabricated patterns.
  • The strategy of adjusting the laser-surface interaction point ensured constant coincidence with the ablated surface normal.
  • The developed system enabled precise control over the laser ablation process on a non-planar surface.

Conclusions:

  • The proposed multi-axis laser milling method offers a feasible solution for continuous laser surface texturing of non-planar surfaces.
  • This technique is particularly effective for miniature parts with large curvatures, overcoming limitations of traditional laser ablation.
  • The study validates the precision and uniformity achievable for microstructuring complex curved surfaces.
  • This work advances the capabilities of laser-based manufacturing for intricate component fabrication.