Selection and optimization of process parameters during multi-pass laser bending process

This paper investigates the process of laser bending, the selection and optimization of process parameters for a multi-pass laser bending process. The aim is to determine the various combinations of laser process parameters, viz., laser power, scan speed, and laser beam diameter, during multi-pass laser bending. The process parameter combinations are selected such that the desired bend angle can be achieved with constraints on the maximum temperature of the workpiece. In order to achieve the desired bend angle, finite element modeling (FEM) simulations using the software package ABAQUS (R) are carried out. The findings reveal that the interaction between laser parameters and material properties has a significant impact on the bend angle; in general, higher laser power combined with slower scan speed results in larger bend angle. A newly developed heuristic algorithm, based on FEM simulations, is used to select the combinations of laser process parameters for the multi-pass laser bending process to achieve the desired bend angle. The algorithm is validated with three examples for getting the desired bend angle of two different materials, viz., AISI 304 and AH36 steel sheets. The results obtained from the developed algorithm are validated by experimental findings. Furthermore, the variation of the total energy required for laser bending and the temperature affected zone (TAZ) at different scan speeds and laser beam diameters is analyzed. The optimization of process parameters is carried out for AISI 304 steel sheet by conducting FEM simulations at different laser beam diameters and scan speeds.