Laser Machining of Structural Alumina: Influence of Moving Laser Beam on the Evolution of Surface Topography

Laser machining technique has emerged as an innovative tool to effectively machine the structural ceramics, which previously was nearly impossible using various conventional machining techniques. However, obtaining a desired surface finish via laser machining is still a critical issue. As many physical phenomena act simultaneously during laser machining, it is very difficult to understand their influence in real time and predict the surface topography. To address this issue, a multiphysics‐based finite‐element modeling approach was implemented to understand the influence of moving laser beam (with lateral overlap) on the generation of corresponding surface topography/profile/roughness during laser machining of structural alumina. A computation model that coupled heat transfer and computational fluid dynamics was designed to understand the combined influence of Marangoni convection, recoil pressure, cooling rates, and surface tension on the evolving surface topography during laser machining of structural alumina under various machining conditions. Both computational and experimental results evidently showed the systematic increase in surface roughness parameters with the increase in lateral overlap (0, 17, 33, 50, 67, and 83%). The results of the computational model are also validated by experimental observations with reasonably close agreement (±3.5%).