Simulation Results from an SPH Approach to Model the Influence of Assist Gas Forces in Laser Cutting

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Kilittuwa Gamage, Ishan Anjana; Baumann, Andreas; Sollich, Daniel; Eberhard, Peter, 2025, "Simulation Results from an SPH Approach to Model the Influence of Assist Gas Forces in Laser Cutting", https://doi.org/10.18419/DARUS-5008, DaRUS, V1
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Description
Laser Cutting
Laser cutting is a non-contact thermal-based material removal method that offers various advantages over conventional machining processes. The workpiece is melted by a high-powered laser beam and the resulting melt is blown away by a jet of gas. The laser assist gas is crucial as it influences the cutting speed, edge quality, and thermal effects, ultimately affecting the overall efficiency and accuracy of the process. However, modeling the laser assist gas domain is highly challenging due to the immense computational costs associated when dealing with shock waves, turbulence, and high speed jet dynamics.

SPH Model of Assist Gas Forces in Laser Cutting
The corresponding publication presents an approach to model the formation of the cutting front and the dynamics of the melt film, influenced by the cutting assist gas forces acting upon it, using the Smoothed Particle Hydrodynamics (SPH) method. SPH is able to deal with large material displacements and moving boundaries occurring in the laser cutting process.
The forces applied to the melt film and cutting kerf are modeled using the Continuum Surface Force approach and boundary particle detection. Consequently, the effects of the assist gas are calculated without modelling the assist gas phase domain, saving a significant amount of computational cost and reducing the complexity of the model. The SPH model is coupled with a ray-tracing scheme and a Fresnel absorption model to determine the laser material interaction.

The presented approach is compared against experimental data from literature, showing good agreement with the experimentally observed cutting front formation, melt rejection, phase transition, dross formation, and striation patterns. The results show that the SPH method can be effectively applied in applications related to laser cutting, showing its potential to design precise and accurate numerical models. Moreover, the proposed parameterized model can help to optimize process parameters to maximize material utilization and reduce energy consumption, operational cost, and processing time during laser cutting.

The videos provided show the simulation results for different boundary conditions and material properties in laser cutting applying the presented SPH model of the assist gas forces.
Subject Engineering
Keyword Laser Cutting, Smoothed-Particle Hydrodynamics, Simulation
Related Publication Is Supplement To: Anjana, I.: Baumann, A.: Sollich, D.; Eberhard, P.: An SPH Approach to Model the Influence of Assist Gas Forces in Laser Cutting
Data Generation Simulation
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CC BY 4.0

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091_pureAl.mp4
MPEG-4 Video - 111.2 MB
Published Apr 28, 2025
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MD5: 5a108e80a73ce20b8b7d6e1ebddc71f2
Simulation Case 091 - Workpiece Material: Pure Al - Laser Power: 1 kW - Laser Feed Rate: 1.75 m/min - Cutting Gas Pressure: 2 bar
Preview "091_pureAl.mp4"
093_temppureAl_reducedSpeed_highPower.mp4
MPEG-4 Video - 106.8 MB
Published Apr 28, 2025
1 Download
MD5: ed4a70d929c30f85104e633abad379dd
Simulation Case 093 - Workpiece Material: Pure Al - Laser Power: 1.1 kW - Laser Feed Rate: 1.4 m/min - Cutting Gas Pressure: 2 bar
Preview "093_temppureAl_reducedSpeed_highPower.mp4"
102_temperature_pres_superslow.mp4
MPEG-4 Video - 33.5 MB
Published Apr 28, 2025
4 Downloads
MD5: 632f9638849d17a9ae423e52270f8417
Simulation Case 102 - Workpiece Material: Pure Al - Laser Power: 1.1 kW - Laser Feed Rate: 1.75 m/min - Cutting Gas Pressure: 2 bar
Preview "102_temperature_pres_superslow.mp4"
103_temperature_pres_superslow.mp4
MPEG-4 Video - 35.2 MB
Published Apr 28, 2025
0 Downloads
MD5: e7dc35af061fc738966b60baec208203
Simulation Case 103 - Workpiece Material: Pure Al - Laser Power: 1 kW - Laser Feed Rate: 1.75 m/min - Cutting Gas Pressure: 4 bar
Preview "103_temperature_pres_superslow.mp4"
111_temp_referenceSim.mp4
MPEG-4 Video - 41.0 MB
Published Apr 28, 2025
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MD5: fc101f57e64f657780cae65b9aab3600
Simulation Case 111 (Reference Simulation) - Workpiece Material: AlMg3 aluminum alloy - Laser Power: 1 kW - Laser Feed Rate: 1.75 m/min - Cutting Gas Pressure: 2 bar
Preview "111_temp_referenceSim.mp4"
112_tempwithoutGas.mp4
MPEG-4 Video - 22.0 MB
Published Apr 28, 2025
0 Downloads
MD5: b96b28d8fa2d612218c15dd7162f81da
Simulation Case 112 (Without cutting gas force) - Workpiece Material: AlMg3 aluminum alloy - Laser Power: 1 kW - Laser Feed Rate: 1.75 m/min - Cutting Gas Pressure: Off
Preview "112_tempwithoutGas.mp4"
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