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Analysis of thermal damage formation and extension mechanism in CFRP short pulse laser cutting based on an inhomogeneous mesoscopic ablation model

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Abstract

One of the effective ways to achieve drilling of Carbon fiber reinforced polymer (CFRP) materials is to use short pulse lasers. However, the existing cutting thermal damage, such as the heat-affected zone (HAZ), can weaken the CFRP mechanical properties. In this paper, a heterogeneous mesoscopic model of transient distribution of short pulse laser ablation heat flow is built to fully explore the formation and extension mechanism of thermal damage. The significant difference in laser interaction thermal effects between fibers and resin leads to the formation of HAZ with exposed fibers. The interface effect exists in the ablation process, which aggravates the matrix damage. The ablation of carbon fibers occurs within the duration of a single laser pulse, and the degree of ablation depends on the pulse energy. Under the coupling of the thermal conduction effect along the fiber axis and the thermal accumulation effect between pulses, the matrix damage extends significantly during the cooling stage. Large pulse repetition frequency increases heat accumulation between pulses and increases matrix damage. There is a new erosion mechanism in that the thermal accumulation behavior leads to the falling off of fragmented carbon fiber filaments. The accuracy of the model was verified through different pulse ablation tests, and the average error of ablation morphology is 11.28%.

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Data availability

The data are available from the corresponding author upon reasonable request.

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Acknowledgements

This work is supported by the National Natural Science Foundation of China (Grant Nos. 52188102, 52375433 & 52305468), the China Postdoctoral Science Foundation (Grant No. 2023M731193) and the Major Program (JD) of Hubei Province (2023BAA015).

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Authors and Affiliations

  1. State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, China

    Youmin Rong, Long Chen, Wenyuan Li, Ya Lu, Yu Huang & Guojun Zhang

  2. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China

    Youmin Rong, Long Chen, Wenyuan Li, Ya Lu, Yu Huang & Guojun Zhang

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  1. Youmin Rong
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  2. Long Chen
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  3. Wenyuan Li
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Correspondence to Wenyuan Li.

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Rong, Y., Chen, L., Li, W. et al. Analysis of thermal damage formation and extension mechanism in CFRP short pulse laser cutting based on an inhomogeneous mesoscopic ablation model. J Mater Sci 59, 8338–8359 (2024). https://doi.org/10.1007/s10853-024-09679-1

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