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Research Papers

Optimization of Spiral Contours for Pulsed Laser Micromachining

[+] Author and Article Information
L. C. Tshabalala

Department of Chemical, Metallurgical and
Materials Engineering,
Tshwane University of Technology,
Pretoria West Campus,
Room 2-152,
Pretoria 0001, South Africa
e-mail: tshabalalalc@tut.ac.za

C. P. Ntuli

Department of Chemical, Metallurgical and
Materials Engineering,
Tshwane University of Technology,
Pretoria West Campus,
Room 2-152,
Pretoria 0001, South Africa
e-mail: 213475258@tut4life.ac.za

S. V. Makama

Department of Chemical, Metallurgical and
Materials Engineering,
Tshwane University of Technology,
Pretoria West Campus,
Room 2-152,
Pretoria 0001, South Africa
e-mail: makamasv@hotmail.co.za

S. Pityana

Council for Scientific and Industrial Research (CSIR),
National Laser Center,
Building 46A, P.O. Box 395,
Pretoria 0001, South Africa
e-mail: spityana@csir.co.za

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received October 24, 2014; final manuscript received May 28, 2015; published online June 24, 2015. Assoc. Editor: Sangkee Min.

J. Micro Nano-Manuf 3(3), 031002 (Sep 01, 2015) (6 pages) Paper No: JMNM-14-1072; doi: 10.1115/1.4030765 History: Received October 24, 2014; Revised May 28, 2015; Online June 24, 2015

In this work, both qualitative and quantitative analytical approaches were used to optimize the spiral contouring technique for complete continuous micromachining of targets. During laser ablation, spiral contours on the target were created by rotational and rastering motions (oscillation) in the x–y plane, while the laser beam position was fixed. Machining quality was characterized using laser to full surface interaction time and surface roughness. The results showed an increased laser–surface interaction time at a reduced raster angle and rastering velocity with high surface roughness at high machining time.

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Figures

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Fig. 1

The ablation chamber with components used during machining

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Fig. 2

Carousel stage with sample holders and possible machining operation trajectories (created using comsol Multiphysics 4.3b)

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Fig. 3

Carousel operation indication sample trajectories: (a) rastering motion in the x–y plane and (b) a CAD model of the sample part indicating the beam trajectory and sample trajectory

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Fig. 4

Laser beam induced spiral contour illustration showing: (a) contours formed during rastering motion in the x–y plane and (b) sinusoidal motion of the carousel in the space and time domain

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Fig. 9

Surface topography plots for the fully machined Si3N4 slabs at ±400 mJ, ε = 11 deg, and ω = 1 deg/s at varied surface treatment time: (a) mean roughness and removal depth plots and (b) the quadrant method used for roughness measurements by the Surftest SJ-201P profiler

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Fig. 8

The Si3N4 slab spiral profiles: (a) stereo microscope images of the fully machined target and (b) the excessive center SEM micrographs at 100 μm

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Fig. 7

Comparison the raster period (T) with the predicted values at varied raster speeds ω = 1–3 deg/s and raster angles with the range of ε = 11 ± 0.46–16 ± 0.21 deg

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Fig. 6

The thermopaper trials for Trials 5–6 at varied beam spot position (black square = target dimensions)

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Fig. 5

The preliminary thermopaper trials used to determine the optimum controller inputs with beam spot at the center (black square = target dimensions)

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