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Research Papers: Heat Transfer in Manufacturing

Numerical Simulation of Transient Three-Dimensional Temperature and Kerf Formation in Laser Fusion Cutting

[+] Author and Article Information
Karim Kheloufi

Laser Material Processing Team,
Centre de Développement des
Technologies Avancées,
P.O. Box 17, Baba-Hassen,
Algiers 16303, Algeria
e-mail: kkheloufi@cdta.dz

El Hachemi Amara

Laser Material Processing Team,
Centre de Développement des
Technologies Avancées,
P.O. Box 17, Baba-Hassen,
Algiers 16303, Algeria
e-mail: amara@cdta.dz

Ahmed Benzaoui

Laboratoire Thermodynamique et
Systèmes Energétiques (LTSE),
Faculté de Physique,
Université des Sciences et de la Technologie,
Houari Boumediene (USTHB),
B.P. 32, El Alia - Bab Ezzouar,
Algiers 16111, Algeria
e-mail: abenzaoui@usthb.dz

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF HEAT TRANSFER. Manuscript received June 8, 2014; final manuscript received May 7, 2015; published online June 9, 2015. Assoc. Editor: Wilson K. S. Chiu.

J. Heat Transfer 137(11), 112101 (Jun 09, 2015) (9 pages) Paper No: HT-14-1391; doi: 10.1115/1.4030658 History: Received June 08, 2014

In the present study, a three-dimensional transient numerical model was developed to study the temperature field and cutting kerf shape during laser fusion cutting. The finite volume model has been constructed, based on the Navier–Stokes equations and energy conservation equation for the description of momentum and heat transport phenomena, and the volume of fluid (VOF) method for free surface tracking. The Fresnel absorption model is used to handle the absorption of the incident wave by the surface of the liquid metal, and the enthalpy-porosity technique is employed to account for the latent heat during melting and solidification of the material. To model the physical phenomena occurring at the liquid film/gas interface, including momentum/heat transfer, a new approach is proposed which consists of treating friction force, pressure force applied by the gas jet, and the heat absorbed by the cutting front surface as source terms incorporated into the governing equations. All these physics are coupled and solved simultaneously in fluent CFD®. The main objective of using a transient phase change model in the current case is to simulate the dynamics and geometry of a growing laser-cutting generated kerf until it becomes fully developed. The model is used to investigate the effect of some process parameters on temperature fields and the formed kerf geometry.

Copyright © 2015 by ASME
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References

Figures

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Fig. 1

Application of gas friction force on the surface melt

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Fig. 2

(a) Computational domain and physical model and (b) Boundary conditions

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Fig. 3

Flowchart for computation process

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Fig. 4

Thermal field in the metal sheet during cutting from the edge; P = 1200 W, Ucut = 30 mm/s, and Ug = 100 m/s

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Fig. 5

Cutting from a point in the top surface

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Fig. 6

Thermal field in the metal during heating stage P = 1200 W, Ucut = 30 mm/s, Ug = 100 m/s (a) t = 0, (b) t = 2 × 10−3, and (c) t = 4.5 × 10−3

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Fig. 7

Thermal field during melting and kerf formation stage P = 1200 W, Ucut = 30 mm/s, Ug = 100 m/s; (a) T = 1.8 × 10−2, (b) t = 2.1 × 10−2, and (c) t = 5.6 × 10−2 s

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Fig. 8

Thermal field in the metal for a fully developed kerf in different views; P = 1200 W, Ucut = 40 mm/s, Ug = 100 m/s

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Fig. 9

Thermal field in the kerf; P = 1200 W, Ug = 100 m/s; (a) Ucut = 10 mm/s and (b) Ucut = 30 mm/s

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Fig. 10

Temperature variation along the melting front (kerf projection on the cutting direction); P = 1200 W, Ug = 100 m/s; (a) Ucut = 10 mm/s and (b) Ucut = 30 mm/s

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Fig. 11

Liquid fraction showing the molten layer in the central plane P = 1200 W, Ug = 100 m/s; (a) Uc=30 mm/s; (b) Uc=20 m/s; (c) Uc=10m/s

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Fig. 12

Velocity magnitude in the liquid film, P = 1200 W, Ug = 100 m/s; (a) Ucut = 10 mm/s and (b) Ucut = 30 mm/s

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Fig. 13

Velocity magnitude variation at the interface along the melting front; (a) Ucut = 10 mm/s and (b) Ucut = 30 mm/s

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Fig. 14

Velocity filed in liquid film

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Fig. 15

Variation of kerf width with cutting speed

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Fig. 16

Effect of assist gas velocity on the kerf width

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