DOCX 0.98 MB - Fraunhofer ILT - Fraunhofer-Gesellschaft

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26 Νοε 2013 (πριν από 4 χρόνια και 1 μήνα)

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F RAUNHOF ER I NSTI TUT E

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Editors

Dipl.
-
Phys.
Axel Bauer

| Leader of Marketing and Communi
c
ation |
Telephone

+49 241 8906
-
194 | axel.bauer@ilt.fraunhofer.de

Petra Nolis M.A.

| PR Consultant | Telephone +49 241 8906
-
662 | petra.nolis@ilt.fraunhofer.de

Fraunhofer Institute for Laser

Technology

ILT

| Steinbachstraße 15 | 52074 Aachen | www.ilt.fraunhofer.de

Using Computer Simulation to Achieve Op
timal Results in Laser
Material

Processing Quickly and Efficiently


At this year’s LASER World of Photonics in Munich, Germany from May 13 to 16, the Fraunhofer
Institute for Laser Techno
logy ILT will be showing how findings won from computer simulation can
be used to optimize manufacturing processes and products. This requires, in particular, the
introduction of new technologies such as the ultra
-
short pulse laser technology. At its joint

stand
330 in Hall C2, the Fraunhofer Institute will be showing, among others, a prototype of the youngest
generation of polygon scanners to guide beams and new optical systems, which put the
“horsepower of USP” on the street. Furthermore, visitors can get

to know the

revolutionary
potential of
“Digital Photonic Prod
uction” at the special stand, 34
0 in Hall C2, on this topic.

Simulation and Modelling for Laser Material Processing

Plant manufacturers and end users of laser processing machines
typically
aim
to optimize t
he manufacturing processes regarding

precision,
reliabilit
y, as well as the time, material and costs involved. To do

this,

they need exact
information

of process
-
relevant
variables

from which
they can derive concrete measures
. Especially with
laser manufacturing
processes, important process
variables

can be
measured

only
poorly
or
not at all in
the few micrometers of the process zone

due to the small
dimensions or the very high temperatures
.


Becoming
Automatic and Cost
-
efficient: Looking Insi
de


To optimize laser processes,

engineers are employing

computer

simulations
more and more often.
The
s
e

enable
them

to “look into” the
process

and


in comparison to experiments


simulations

c
an be more
easily automated as well as being
more cost
-
efficient.
Moreover
, in
such
simulations, deviations and measurement inaccuracies can be not only
excluded, but
also can be specifically taken into account
. This way, key
positions can be found, problems recognized early and, thus, solved. For
ar
ound twenty years, a twelve
-
member team of highly specialized
scien
tists at the Fraunhofer ILT has

been working solely on the computer
-
supported simulation of laser processes.

At their disposal is a high
-
performance
cluster of computers
,

which was set up o
n the Fraunhofer

premises

within the scope of the “Center for Nanophotonics” in 2010. This
way, the experts in Aachen can simulate complex questions from laser
-
material processing with high resolu
tion in the briefest computing

time
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and derive concrete appr
oaches to solutions

from this information
.

When
lasers are used to cut display glass, for example, simulation of the
processes can both increase the ablation speed as well as prevent
damages to the glass.


Simulated Processes: Application Examples at the L
ASER World of Photonics

On account of

the systematic findings from the simulations, the ILT
experts
can
contribute
significantly
to
the p
roduct and process
development of their industrial partners.
At the LASER World of Photonics
t
hey will be presenting f
ive examples of
this kind of
successful
cooperation
. Among these belong simulating

the laser processes of
cut
ting
display glass with ultra
-
short pulse laser
s

for TRUMPF Laser

Technology
, the water
-
guided laser cutting for SYNOVA as well as the
optimization

of metal cutting for TRUMPF
Machine Tools
. Thanks to the
findings of the computer simulations
,

the Fraunhofer ILT

was able to
optimize

laser beam sources for ROFIN
-
SINAR. In the sector of produ
ct
optimization, free
-
form lens

prototypes were
calculated for

the
automo
tive

supplier

HELLA.


Using USP Lasers Economically with Beam Guidance

Ultra
-
short pulse laser systems are achieving new records almost daily
regarding laser power and pulse rates.

And yet
in the power range of 50
to 1,000 watts,
o
nly a small
part of the energy they have can be used
effectively for many applications
. If

the laser

power is too high when it is
coupled into the work
piece
at

the processing point,

bulges

from the
melting effects occur due to the high thermal load, leading to
poor
pr
ocessing results
.
Now, t
he research work at the Fraunhofer ILT
is
looking at making the high power of USP lasers
useful for material
processing: f
or example, by dividing the laser beam into several
individual beams, which then can process the component sim
ultaneously.
This multi
-
beam technique is used, among others, to generate periodic
microstructure
s
.


Planar

Ablation at the Speed of
Sound

A further approach to using the high laser power exists in guiding the
laser at high speeds. To achieve this, ILT sci
entists have developed a
polygon scanner system: in it, a polygon mirror rotates at a high, constant
revolution and guides the beam along a line on the workpiece. As the
laser beam is guided along this line at the speed of sound, the high laser
power is di
stributed evenly along the work piece. An axis perpendicular to
this line moves the workpiece so that the area to be processed is
clamped. The polygon scanner has a maximum aperture of 20 mm and





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reaches scanning speeds of up to 360 m/s at a focal length of

163 mm.
Thus, it is able to process a surface area of 100 x 100 mm
2

with a lateral
resolution of 20 µm in 3 seconds. To generate 2.5 D structures, the
material is ablated layer by layer at a depth resolution of up to 100 nm. In
comparison to this new polygon scanner, galvanic meter scanners with
comparable apertures are t
ypically used at scanning speeds of 1
-
5 m/s.
Currently, researchers at the Fraunhofer ILT have succeeded in gating the
laser, according to the position of the polygon motor and the workpiece
axis, at up to 40 MHz; this way, the work piece is processed at t
he right
location. The challenge facing engineers for future developments of the
polygon scanner consist in modulating the laser power corresponding to
this precise gate signal, since current laser modulators can be operated at
a maximum pulse repetition r
ate of 2 MHz.



Live Presentation at the LASER World of Photonics
.

This scanning technology is particularly suitable for processing surfaces,
since the workpiece
is

processed in lines.
T
he polygon scanner system
can be employed, in particular, for
the str
ucturing of printing and coining
plat
es, as well as injection molds
, for the generation of light guiding
structures in the lighting industry or for leather

grain
structures in the
automobile and textile industries. Further applications are the cutting of
h
igh performance ceramic
s including structures of form
-
fit

bonds as well
as wafer processing in the solar and semi
-
conductor industry. The process

can also be transferred to
spatial thin film processing for roll
-
to
-
roll
processing. At the LASER World of Pho
tonics, experts of the Fraunhofer
ILT

will be presenting the p
olygon scanning technology
by making

metal
lic
business cards
.


Digital Photonic Production
DPP


Digital Photonic Production


is the name for the laser
-
based generation
of components or products in nearly any complexity from digital data. The
technology ranges from generative processes all the way
to high
-
power
ultra
-
short pulse

laser for micro
-
processing. In contrast to convent
ional
manufacturing processes, the tool “light” can be used to manufacture the
smallest lot sizes as well as complex components of the smallest
dimensions fr
om the most differing materials and
it can
do this cost
effectively. That is why

many speak
of
a “n
ew technological revolution

in
connection with this technology.
At Stand 340 in Hall C2, the Fraunhofer
Institute will be demonstrating, jointly with the Chair for Laser Technology
ILT of the RWTH Aachen University, the enormous potential of DPP using
sel
ected examples from the automobile, aviation and aerospace sectors,





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energy technology,
ultra
-
light

construction
and medical technology as
well as in the consumer sector.


Press Tour
at

Fraunhofer

Stand

Tuesday, 14 May
2013

11:00
-

12:00 h

LASER World of
PHOTON
ICS 2013

Hall
B2, Stand 421
and Hall

C2, Stand 330



Under the motto “Customized Solutions,” the Fraunhofer researchers will
be showing new developments from laser technology. Highlights include
polygon scanner systems, 3D object recognition, ultra
-
flat microscopes,
3D high speed measuring as well as an innovative compact processing
head for laser wire cladding.

The press tour begins at 11:00

a.m. in Hall B2 at Stand 421 displaying
production technology for optics and ends in Hall C2 at Stand 330
with
laser systems for manufactur
ing. At

lunch,

which follows directly
thereafter
, visitors

will have the

opportunity to discuss these innovations

with the scientists.


Lecture languages: German a
nd Englis
h (
with interpretation
)





Picture:

Computer

S
imu
lation

for Cutting of
Display

G
las
s
.

Source
: Fraunhofer ILT, Aachen.










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The
Fraunhofer
-
Gesellschaft

is the leading organization for applied research and development in Europe. Under its
leadership, 66 institutes work at locations all over Germany. More than 22,000 employees work with an annual research
volume of 1.9 billion euros. From this 1.6 billion
euros fall under contracted research. The
Fraunhofer
-
Gesellschaft

generates
over 70 percent of these services from contracts from industry and publicly funded research projects. International branch
offices ensure contact to the most important current and
future scientific and economic sectors.



Contact Partners

D
r. Jens Schüttler

|


Simulation and Mode
ling | Teleph
on
e

+49 241 8906
-
680


|

jens.schuettler@ilt.fraunhofer.de

Prof. Wolfgang Schulz


|

Leader of
the Department of

Non
-
linear Dynamics of the
Laser M
anufacturing

P
rocess

NLD

Telephone

+49 241 8906
-
204

|

wolfgang.schulz
@ilt.fraunhofer.de

Dipl.
-
Phys. Oliver Nottrodt

|
Pro
cess Control

and
System

Technology

| Telephone

+49 241 8906
-
625 |
oliver.nottrodt@ilt.frau
nhofer.de

Peter Abels

|
Group
Leader Process Control

and System Technology
| Telephone

+49 241 8906
-
428 |
peter.abels@ilt.fraunhofer.de

Fraunhofer
Institut
e for

Laser

Technology

ILT, Aachen | www.ilt.fraunhofer.de


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