Abstract

Laser forming (LF) is a non-contact method to shape metallic sheets and tubes by induced thermal stress without melting using a de-focused laser beam. Laser forming offers the industrial promise of controlled shaping of metallic and non-metallic components for prototyping, correction of design shape or distortion and precision adjustment applications. In order to fulfil this promise in a manufacturing environment the process must have a high degree of control, be repeatable and have a minimal impact on the material and mechanical properties of the part to be formed. In order to demonstrate the capability of the LF process a study is presented in this paper on the 3D Laser Forming of ERW steel square tubes SHS EN10305-5 E220 +CR2 (1.5x25x25mm and 1.5x50x50mm 300mm long tube) using a 1.5kW CO2 laser and industrial 5 axis gantry. Strategies have been developed for out of plane bending with specific emphasis on process throughput balanced with minimising adverse localised changes to material properties that could lead to stress concentration features in a component in service. Presented in this paper is empirical 3D LF shape data verified by a scanning laser profiler, a metallurgical study, hardness testing and a FEM model developed in Comsol Multi-Physics. The results of these studies were employed to develop optimised scan strategies for the controlled laser forming of the ERW steel square tubes within strict metallurgical constraints.