Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Laser process simulation available as app for first time

23.11.2015

In laser material processing, the simulation of processes has made great strides over the past few years. Today, the software can predict relatively well what will happen on the workpiece. Unfortunately, it is also highly complex and requires a lot of computing time. Thanks to clever simplification, experts from Fraunhofer ILT are now able to offer the first-ever simulation software that calculates processes in real time and also runs on tablet computers and smartphones. The fast software enables users to do without expensive experiments and to find optimum process parameters even more effectively.

Before now, the reliable simulation of laser processes was a job for experts. Armed with sophisticated software packages and after many hours on computer clusters, they are now able to simulate a wide variety of processes with a good degree of reliability. However, this kind of elaborate work is hardly suitable for ordinary users in factories, who tend to rely on the system providers’ technology tables when setting up new processes.


Picture 1: Reduced drilling simulation with beam distribution. The red line shows the good correspondence with the experimental result.

Source: Fraunhofer ILT, Aachen/Germany


In AsymptoticDrill, the new license software, many parameters can be changed using sliders even with a simplified model.

Source: Fraunhofer ILT, Aachen/Germany

New software slashes computing time

Simulation experts at the Fraunhofer Institute for Laser Technology ILT have developed new software that requires much less in the way of resources, such that it can even run on tablet computers and smartphones. Individual parameters can be adjusted using sliders – the simulation result appears in an adjacent window and changes in real time.

This is made possible by an application-specific reduction of the computing models, a process in which certain simplifications are introduced depending on the respective application. Because these simplifications dramatically reduce the complexity of calculations, they produce a result much more quickly.

Example: laser drilling

Conventional simulation programs deliver a complex representation of the processes involved in the interaction of laser beam and material. More than anything else, users are interested in things like how the conicity of a drill hole changes when parameters such as focal position or spot diameter are adjusted. The simplified simulation allows the influence of such parameters to be properly investigated, and the results match up with experimental data very well: Picture 1 shows just such a simulation using the new computing model compared to the thin section of a drill hole.

In contrast to earlier methods and to regular experiments, now the effects of changed parameters are displayed immediately. Changing individual parameters is virtually child’s play, and the results appear instantaneously in the adjacent window (Picture 2).
This means that the simulation can be carried out directly at the laser machine. Time-intensive experiments are no longer required and set-up processes can be completed much faster.

Simulation for advanced users: metamodeling

The high speed of simulation also opens up a range of entirely different options, such as metamodeling. Suitable for complex simulations with many parameters, metamodeling involves generating high-dimensional data sets with the parameters and several evaluation criteria for process and product quality. These sets can then be used to create individual process maps (hyper slices) that show the dependency of the results of individual parameter pairs. The quality of a result is always displayed using color coding so that optimum parameters are immediately visible.

This advanced simulation makes it possible to find global and local extreme values – for example, parameter sets for best and worst quality – through mathematical manipulation of the data sets. Such simultaneous optimization of multiple parameters is scarcely possible by experimental means. This means that new methods in manufacturing such as those of iterative design can be executed much faster.

Customized software for use in factories

The idea for the new software developed out of a particular order for a large customer. Further contracts have been concluded in the meantime, but the software is available for all customers. Depending on the planned application, it will be specially modified by the experts at Fraunhofer ILT to facilitate optimum results. The know-how resides in the skillful simplification of traditional models.

However, the software’s potential does not stop there; time-intensive calculations exist in many areas of industry. In the automotive sector, for example, the simulation of crash tests still uses up considerable computing capacity. Transferring the principle of reduced models promises substantial savings there, too.

Contact

Dipl.-Phys. Torsten Hermanns
Chair for Nonlinear Dynamics of
Laser Processing NLD
RWTH Aachen University
Phone +49 241 8906-8367
hermanns.torsten@nld.rwth-aachen.de

Prof. Dr. Wolfgang Schulz
Head of the Chair for Nonlinear Dynamics of
Laser Processing NLD
RWTH Aachen University
Group Manager Simulation and Modeling
at the Fraunhofer ILT
Telephone +49 241 8906-204
wolfgang.schulz@ilt.fraunhofer.de

Fraunhofer Institute for Laser Technology ILT
Steinbachstraße 15
52074 Aachen, Germany

Weitere Informationen:

http://www.ilt.fraunhofer.de
http://www.nld.rwth-aachen.de

Petra Nolis | Fraunhofer-Institut für Lasertechnik ILT

Further reports about: ILT Laser Laser Processing Lasertechnik Nonlinear factories processes

More articles from Information Technology:

nachricht Reversing cause and effect is no trouble for quantum computers
20.07.2018 | Centre for Quantum Technologies at the National University of Singapore

nachricht Study suggests buried Internet infrastructure at risk as sea levels rise
18.07.2018 | University of Wisconsin-Madison

All articles from Information Technology >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Future electronic components to be printed like newspapers

A new manufacturing technique uses a process similar to newspaper printing to form smoother and more flexible metals for making ultrafast electronic devices.

The low-cost process, developed by Purdue University researchers, combines tools already used in industry for manufacturing metals on a large scale, but uses...

Im Focus: First evidence on the source of extragalactic particles

For the first time ever, scientists have determined the cosmic origin of highest-energy neutrinos. A research group led by IceCube scientist Elisa Resconi, spokesperson of the Collaborative Research Center SFB1258 at the Technical University of Munich (TUM), provides an important piece of evidence that the particles detected by the IceCube neutrino telescope at the South Pole originate from a galaxy four billion light-years away from Earth.

To rule out other origins with certainty, the team led by neutrino physicist Elisa Resconi from the Technical University of Munich and multi-wavelength...

Im Focus: Magnetic vortices: Two independent magnetic skyrmion phases discovered in a single material

For the first time a team of researchers have discovered two different phases of magnetic skyrmions in a single material. Physicists of the Technical Universities of Munich and Dresden and the University of Cologne can now better study and understand the properties of these magnetic structures, which are important for both basic research and applications.

Whirlpools are an everyday experience in a bath tub: When the water is drained a circular vortex is formed. Typically, such whirls are rather stable. Similar...

Im Focus: Breaking the bond: To take part or not?

Physicists working with Roland Wester at the University of Innsbruck have investigated if and how chemical reactions can be influenced by targeted vibrational excitation of the reactants. They were able to demonstrate that excitation with a laser beam does not affect the efficiency of a chemical exchange reaction and that the excited molecular group acts only as a spectator in the reaction.

A frequently used reaction in organic chemistry is nucleophilic substitution. It plays, for example, an important role in in the synthesis of new chemical...

Im Focus: New 2D Spectroscopy Methods

Optical spectroscopy allows investigating the energy structure and dynamic properties of complex quantum systems. Researchers from the University of Würzburg present two new approaches of coherent two-dimensional spectroscopy.

"Put an excitation into the system and observe how it evolves." According to physicist Professor Tobias Brixner, this is the credo of optical spectroscopy....

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Leading experts in Diabetes, Metabolism and Biomedical Engineering discuss Precision Medicine

13.07.2018 | Event News

Conference on Laser Polishing – LaP: Fine Tuning for Surfaces

12.07.2018 | Event News

11th European Wood-based Panel Symposium 2018: Meeting point for the wood-based materials industry

03.07.2018 | Event News

 
Latest News

A smart safe rechargeable zinc ion battery based on sol-gel transition electrolytes

20.07.2018 | Power and Electrical Engineering

Reversing cause and effect is no trouble for quantum computers

20.07.2018 | Information Technology

Princeton-UPenn research team finds physics treasure hidden in a wallpaper pattern

20.07.2018 | Materials Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>