LASER THERMAL FORMING OF SHEET-METAL PARTS USING DESK-TOP LASER SYSTEMS

The bending of flat sheet metal materials using a laser process is not new to the metals industry. However, refining the process to the poin t where an angle bend can be predicted is significant when developing prototypes of small and large components [M. Pridham and G. Thomson, M ater. World 2, 574 (1994)]. The methods and process developed to perfo rm this task along with applications of the laser forming process are presented, and key elements to maintain consistency and process repeat ability are identified. A 50 W CO2 Desktop laser system provided the c ontrols necessary to create specific shapes from CRES (302) with thick ness varying from 0.26 to 0.64 mm. Effects of variations of beam diver gence, feed rate, laser power, and pulses per inch, are presented. Mat erial surface condition and material preparation techniques have signi ficant effects on the overall outcome of forming and are therefore dis cussed. Compound radius bends were performed by calculating the effect s of simple bends in conjunction with multiple passes. Experimental da ta were compiled and a section on the analysis of these data is also p resented. (C) 1998 Laser Institute of America.