Heat accumulation between scans during multi-pass cutting of carbon fiber reinforced plastics

Matrix evaporation caused by heat accumulation between scans (HAS) was studied in the case of multi-pass scanning of a laser beam over the surface of carbon fiber reinforced plastic (CFRP). The experiments were performed in two regimes, namely, in the process of CFRP cutting and in the regime of low-fluence irradiation avoiding ablation of carbon fibers. The feature of the ablation-free regime is that all absorbed energy remains in the material as heat, while in the cutting regime the fraction of residual heat is unknown. An analytical model based on two-dimensional (2D) heat flow was applied to predict the critical number of scans, after which the HAS effect causes a distinct growth of the matrix evaporation zone (MEZ). According to the model, the critical number of scans decreases exponentially with increasing laser power, while no dependence on the feed rate is expected. It was found that the model fits well to the experimental data obtained in the ablation-free regime where the heat input is well defined and known. In the cutting regime the measured significant reduction of the critical number of scans observed in deep grooves may be attributed to transformation of the heat flow geometry and to an expected increase of the residual heat fraction.