Laser Beam Machining (LBM)

In laser beam machining, the source of energy is a laser (Light

Amplification by Simulated Emission of Radiation), which focuses
optical energy on the surface of the workpiece. A laser beam can melt
and vaporize diamond when focused by lens system, the energy
density being of the order of 105 kW/cm2. Such tremendous energy
release is due to certain atoms which have higher energy level and
oscillate with particular frequency.

There are several types of lasers used in manufacturing operations,

e.g., solid state, gas, liquid and semi conductor. For machining and
welding, high power lasers are required and, in general, only the solid
state lasers can provide the required power levels.

The most commonly used solid-state laser is the ruby laser (crystalline
aluminium oxide or sapphire). These lasers are fabricated into rods
about 150 mm long and their ends are furnished to close optical
tolerances.

(a) Schematic illustration of the laser-beam machining process. (b) and

(c) Examples of holes produced in nonmetallic parts by LBM.

The ruby crystal is doped with a small amount of chromium oxide. The laser
is pumped by a flash of high intensity light (xenon-filled flash lamp). The
xenon lamp is fired by discharging a large capacitor through it (electric

power of 250 to 1000 watts may be needed for this). The intense radiation
from the lamp excites fluorescent impurity atoms (chromium atoms) to a
higher energy level. When the atoms fall back to the original energy level
through a series of energy levels, an intense beam of visible light is emitted.
When this light is reflected back from the coated rod ends, more atoms are
excited and stimulated to return to their ground level. This chain reaction
results in a stimulated avalanche of light, some of which is transmitted
through the reflecting coatings (about 80% reflective). This light is highly
coherent in time and space, that is, it has a very narrow frequency band, is
highly in phase, and is quite parallel. When this light is focused with ordinary
lenses at spot on the workpiece, high energy density is obtained which will
melt and vaporize the metal.

Advantages
There is no direct contact between tool and workpiece. As such
no tool wear problems are faced. Metal, non-metal irrespective of
their brittleness and hardness, and even soft metals like plastics
and rubber can be machined.
Laser beam can be sent to longer distances, without diffraction.
It can also be focused at one place thereby generating lot of
heat. It is thus possible to weld, drill and cut areas not readily
accessible.
The advantages of laser welding are that heat treated and
magnetic material can be welded without losing their properties
all over the material except a small region of heat-affection.
Laser welding is possible in any environment through transparent
materials and magnetic fields as well. Distortion is negligible and
any two materials can be joined together. However, it is
important that the vaporization of the metal must be avoided.
Micro-sized holes can be laser drilled in difficult-to-machine or
refractory materials. Precision location is ensured by focusing of
the beam. Deep holes of very short diameter can be drilled by
using unidirectional multiple pulses.
Beam configuration and size of exposed area can be easily
controlled.

Disadvantages
High initial cost and short life of flash lamp
Safety procedures to be followed strictly
Over-all low efficiency (0.3% to 0.5%)
Very low material removal rate
Notable to drill too deep holes
Machined holes not round and straight and
No possibility of machining some plastics which bum or char.

Applications
Used for making very small holes (holes in rubber baby bottle
nipples), difficult welding of non-conductive and refractory
materials, cutting complex profiles in thin and hard materials. Also
used for partial cutting or engraving.
Can be used for mass micro-machining production.
Can also be used for selective heat treating of materials
It is also sometimes used for dynamic balancing of rotating parts.
It is very useful for producing very fine and minute holes etc.