Integrated Laser Milling Center for Complete Machining

St. Nowotny, S. Scharek, T. Naumann, R. Gnann*,Th. Heptner**, E. Beyer

Fraunhofer-Institute for Materials and Beam Technology
Dresden, Germany
*Maschinenfabrik ARNOLD, Ravensburg, Germany
**NcSoft Wagner, Schwerin, Germany

Abstract

The repair and quick geometrical changes of components and tools are currently the
most important applications of laser build-up welding. Advanced laser technology
permits the integration of the main process steps into one machining center for a very
efficient and flexible manufacturing process.
The solution presented in this paper consists of a 3axes CNC milling machine, in which a
3 kW Nd:YAG laser, a coaxial powder nozzle, and a digitizing system are integrated. All
functions (data processing, laser process, powder feeding, and milling) are controlled by
one CNC controller using specially developed software. In the first step the workpiece
needs to be adjusted to the machine table. Then the contour of the damaged surface is
determined by either an optical or mechanical digitizing system. Using the resulting
data, a software system generates automatically the laser build-up strategy and the CNC
programs for the laser and the milling processes. After laser freeforming, a raw piece
with an oversize of 0.3 to 0.6 mm is made. From this geometry the end contour is milled
with an accuracy of some 10 microns. This way the machine produces a completely fi-
nished tool.

1. Introduction

Recent laser techniques of repair and freeforming include the process steps import
of 3D data or digitizing of the workpiece, data processing, 3D modeling, CNC
programming, material build-up, and finish machining. Usually, these manufacturing
sections are carried out sequentially on different machines. The consequence is an
increased effort of transportation and adjustment of the workpiece as well as of CNC
programming. Especially for remanufacturing of parts, time and costs of programming
and adjustment often exceed the effort of the actual material replacement. Thus, the
economy of the whole process is affected and some potential laser applications in this
field cannot be realized first of all because of financial reasons. To solve this problem,
the hard- and software necessary for the realization of all process steps was integrated
into a CNC milling center. Specially developed software connects laser, machine tool,
and all additional components, so that the whole machining process takes place
consequently in one machine and in a fixed clamping of the workpiece.
 2. CAD import/digitizing and programming system

The base of 3D modeling, data processing, and programming is the specially deve-
loped software system DCAMnc for the laser/milling combination. DCAM is a software
package consisting of the three tools explained in the following.

DCAMcad
Using this tool, 3D CAD data can be
imported in formats as DXF, SAT, IGES, or
HPGL. These data can be either the result
of the constructive work of designers
(freeforming or rapid prototyping, Fig. 1)
or of the calculation of a volume
difference between a wear damaged
surface of a tool and the constructive
given geometry of the tool in the
undamaged state (remanufacturing). In
both cases the software generates a 3D
model of the geometry to be laser
generated including the process
dependent oversize. In a second step the Fig.1: CAD model of a mold insert
modeled volume is cut up into defined
horizontal layers (»slicing«), Fig. 2, and
optimized laser tracks for filling these
layers are calculated. In this connection,
the DCAM system also supports the
selection of a suitable strategy of the laser
build-up process. To say, the placement of
contour and filling tracks of each 2D layer
as well as the stacking of these layers to
the 3D part is determined with respect to
technical and economical requirements.

DCAMcam
For the combination of laser build-up
welding and milling on one machine a
special postprocessor has been developed. Fig.2: Sliced CAD model
It generates the CNC programs for both
laser and milling on the base a uniform CAD model. This way, the effort for
programming is reduced considerably and the direct and complete manufacturing of
parts and tools is possible very quickly and efficiently.
 DCAMscan
CNC data of the damaged parts,
which should be repaired, are commonly
not available. In this case DCAMscan can
be used for the quick scanning of 3D
shaped surfaces. The resulting data are
transferred to DCAMcad and processed
with this software tool. In the easiest and
most inexpensive variant the digitizing
system consists of a mechanical, hand-
guided 5axes tactile arm, Fig. 3. The
accuracy is about 0.2 mm, and the
maximum working radius 1,800 mm.
Additionally, the system is compatible to
other commercially available optical or
Fig. 3: Digitizing system with manual tactile arm
tactile digitizing systems.

3. Laser technology

For build-up welding the

beam of a 3 kW Nd:YAG laser is
integrated into the milling
center. The focusing optic,
combined with the coaxial
cladding unit, is mounted at the
Z-axis of the machine, Fig. 4.
The coaxial nozzle, Fig. 5, is an
advanced version with reduced
size and variable nozzle tips for
a better adaptation to the given
application and to the easier
maintenance. The diameter of
the powder focus lies between Seite
erstellt: 05.07.2001 gedruckt: 00.00.0000

1 und 2 mm, depending on the

powder type and the powder Fig. 4: Integrated laser optic Fig. 5: coaxial powder nozzle
feed rate. The powder efficiency and cladding unit
amounts at least 60 % if the
melt bath diameter is not less
than 1.5 mm. Powder feed rates from 1 to 20 g/min are possible (e.g. Ni base alloys).
The new nozzle type is designed for a minimum focal length of 70 mm, what is
especially interesting for diode laser cladding applications.
 Currently 3D structures of Ni and Co
base alloys as well as steel can be
produced with this equipment. Using a
sealed inert gas chamber, also Ti, Al, and
Cu alloys are possible. Fig. 6 shows exem-
plarily the cross section of a generated
structure of Stellite 21. The structure is
completely dense and flawless, even
without intermediate machining. The
accuracy depends on the powder and the 1 mm
process parameters. Typically it lies in the
range of 0.3 to 0.6 mm. Fig. 6: Cross section of a multi layer structure
of Stellite 21
4. Milling center

The basis of the integrated solution is

a 3 axes CNC milling center with a
40,5” x 20“ machine table and 30” x 20”
x 27,5” X-, Y- & Z-axes, Fig. 7. The
maximum spindle speed is 10,000 rpm.
To assemble all process steps and to
connect all components, the CNC con-
troller has got interfaces to two lasers
(Nd:YAG and diode), 2 powder feeding
lines, and to the DCAM system. Addi-
tionally the machine is equipped with an
interface to a plasma build-up welding
system (PTA). This can be used for a
laser/plasma combination to increase effi- Fig. 7: 3 axes CNC laser milling machine
ciency and productivity when larger volu-
mes should be build up.

Fig. 8 shows as example

a mold insert which was
directly generated from the
CAD model of Fig. 1. The
raw tool has an oversize of
0.6 mm in this case and a
hardness of 35 HRC. The fi-
nish machining was carried
out with a milling cutter of Fig. 8: Laser generated mold insert of Stellite 21
coated hard metal and left:
eft: as-generated right: partly finish machined
without lubricant/coolant.
The result is shown in Fig. 8, right photograph. For this presentation, only one half of
the tool is machined in order to allow a comparison between the as-generated and the
finish machined surface.

5. Acknowledgment

Parts of the research presented here were founded by the German Ministry of Education
and Research (BMBF) and by ARNOLD, Rofin Sinar, and DaimlerChrysler.