Process analysis and simulation

The systematic optimization laser material processing techniques requires a sound understanding of the process flow. The understanding of the process is gained by experimental (process monitoring) and computational (simulation) methods. The increasing computer performance and user-friendliness of simulation software bring about a wider spectrum of applications and less computational costs for finite element calculations. In addition, for process analysis, conventional and new measurement techniques open up new opportunities for a more precise registration of real conditions within the process.

The combination of simulation and analysis reduces the time required for developing the process. The aim is to replace the number of assumptions produced by the simulation by detailed boundary conditions resulting from experimental data of process analysis.

At LZH simulation is used in different fields:

• Thermal simulation (process analysis using pyrometry, thermo camera, HDRC camera [exponentially growing optical susceptibility])
• Mechanical simulation (process analysis using mechanical-technological property measurements [e.g. motor tractor] with ESPI fine expansion measurement)
• Simulation of material transport processes in laser-induced molten metals (process analysis using a high-speed camera and X-ray micro focus transmitted light)
• Microstructure simulation (process analysis using metallographic methods, such as microscopy, SEM, TEM)

The process technique for temperature-controlled laser hardening using pyrometric temperature measurement is simulated by a thermal model. The calculation result is so precise that no further optimization of the processing strategy is required; the real process can be started immediately.