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Predictive modeling, simulation, and optimization of laser processing techniques
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Criales Escobar, Luis Ernesto. Predictive modeling, simulation, and optimization of laser processing techniques. Retrieved from https://doi.org/doi:10.7282/T3SX6GCJ

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TitlePredictive modeling, simulation, and optimization of laser processing techniques
NameCriales Escobar, Luis Ernesto (author); Ozel, Tugrul (chair); Albin, Susan (internal member); Jeong, Myong-Kee (internal member); Donmez, Alkan (outside member); Jaluria, Yogesh (outside member); Rutgers University; Graduate School - New Brunswick
Date Created2016
Other Date2016-05 (degree)
SubjectIndustrial and Systems Engineering, Manufacturing processes, Three-dimensional printing, Lasers--Industrial applications
Extent1 online resource (xxix, 271 p. : ill.)
DescriptionOne of the most frequently evolving areas of research is the utilization of lasers for micro-manufacturing and additive manufacturing purposes. The use of laser beam as a tool for manufacturing arises from the need for flexible and rapid manufacturing at a low-to-mid cost. Laser micro-machining provides an advantage over mechanical micro-machining due to the faster production times of large batch sizes and the high costs associated with specific tools. Laser based additive manufacturing enables processing of powder metals for direct and rapid fabrication of products. Therefore, laser processing can be viewed as a fast, flexible, and cost-effective approach compared to traditional manufacturing processes. Two types of laser processing techniques are studied: laser ablation of polymers for micro-channel fabrication and selective laser melting of metal powders. Initially, a feasibility study for laser-based micro-channel fabrication of poly(dimethylsiloxane) (PDMS) via experimentation is presented. In particular, the effectiveness of utilizing a nanosecond-pulsed laser as the energy source for laser ablation is studied. The results are analyzed statistically and a relationship between process parameters and micro-channel dimensions is established. Additionally, a process model is introduced for predicting channel depth. Model outputs are compared and analyzed to experimental results. The second part of this research focuses on a physics-based FEM approach for predicting the temperature profile and melt pool geometry in selective laser melting (SLM) of metal powders. Temperature profiles are calculated for a moving laser heat source to understand the temperature rise due to heating during SLM. Based on the predicted temperature distributions, melt pool geometry, i.e. the locations at which melting of the powder material occurs, is determined. Simulation results are compared against data obtained from experimental Inconel 625 test coupons fabricated at the National Institute for Standards & Technology via response surface methodology techniques. The main goal of this research is to develop a comprehensive predictive model with which the effect of powder material properties and laser process parameters on the built quality and integrity of SLM-produced parts can be better understood. By optimizing process parameters, SLM as an additive manufacturing technique is not only possible, but also practical and reproducible.
NotePh.D.
NoteIncludes bibliographical references
Noteby Luis Ernesto Criales Escobar
Genretheses, ETD doctoral
Persistent URLhttps://doi.org/doi:10.7282/T3SX6GCJ
Languageeng
CollectionGraduate School - New Brunswick Electronic Theses and Dissertations
Organization NameRutgers, The State University of New Jersey
RightsThe author owns the copyright to this work.
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