Laser micro-machining of freeform surfaces: accuracy, repeatability and reproducibility achievable with multi-axis processing strategies

Themistoklis Karkantonis*, Pavel Penchev, Vahid Nasrollahi, Hoang Le, Tian See, David Bruneel, Jose Ramos-de-Campos, Stefan Dimov

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

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Abstract

The requirements that complex 3D miniaturised components have to satisfy are constantly increasing for various application areas, e.g. in aerospace, biomedical and electronics, and hence there is a sustained drive to broaden the capabilities of precision manufacturing processes. In this regard, state-of-the-art Laser Micro-Machining (LMM) systems have been attracting significant industrial interest with their emerging capabilities for multi-axis machining. However, intrinsic limitations of component technologies of such systems can impact the machining accuracy, repeatability, and reproducibility (ARR), especially in complex processing strategies requiring the simultaneous use of multiple axes, and consequently to affect the overall processing uncertainty. Herein, the aim of this research is to propose a systematic method for assessing the overall performance of such LMM systems when they are deployed for laser structuring/patterning/texturing of freeform surfaces. In particular, the method employs a series of laser processing tests on spherical samples to quantify the contributions of different error sources on the machining ARR when implementing simultaneous multi-axis processing strategies under quasi-static and dynamic conditions. An experimental validation of the proposed method is conducted on a representative state-of-the- art LMM system and then conclusions are drawn about its capabilities to determine the processing ARR of multi-axis LMM systems. This research provides an insight into the limitations and manufacturing challenges in deploying such systems for the fabrication of complex 3D components.
Original languageEnglish
Pages (from-to)233-247
Number of pages15
JournalPrecision Engineering
Volume78
Early online date28 Aug 2022
DOIs
Publication statusPublished - Nov 2022

Bibliographical note

Funding Information:
The research reported in this paper was supported by a H2020 Factory of the Future projects , “High-Impact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities” (HIMALAIA) (grant no. 766871 ). The authors would like to thank the Manufacturing Technology Centre (MTC) for the financial support of Themistoklis Karkantonis's Ph.D. research and acknowledge also the collaboration with LASEA SA, Belgium within the framework of the ESIF project “Smart Factory Hub” (SmartFub) (grant no. 50R18P02795 ).

Publisher Copyright:
© 2022 Elsevier Inc.

Keywords

  • Machining test
  • Laser micro-machining system
  • Performance evaluation
  • Precision metrology
  • Freeform surface
  • Multi-axis simultaneous laser processing
  • Accuracy
  • Repeatability
  • Reproducibility
  • Uncertainty

ASJC Scopus subject areas

  • Engineering(all)

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