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Laser Forming of Complex Structures

High-intensity laser beams can be used to heat and bend sheet metal, but the mechanisms of the laser forming (LF) process are not well understood or precisely controllable. The objective of the NIST-sponsored project "Laser Forming of Complex Structures" is to develop technologies for controllable, repeatable laser forming processes that shape and re-shape a wide array of forms and compositions. One such form is embodied in turbomac hinery compressor airfoils, characterized by complex 3D geometries and large thickness variation. LF can be used to alter or "tune" the shape of these parts into their final tolerances. To gain insight in applying laser forming to compressor airfoils, LF analysis and process synthesis on tapered-thickness plates is conducted. The bending mechanisms and parametric effects on the deformation characteristics of tapered -thickness plates are investigated. A strategy of LF process synthesis of doubly curved shapes is also presented. The scanning paths are determined by considering the different weights of bending and in-plane strain. A thickness-dependent database is established by LF simulation and experiment, and the heating conditions are determined by matching the ratio of bending strain to in -plane strain between the required values and the laser forming values. The analysis and the synthesis are validated by numerical simulation and experiments. As an example of industrial application, 3D shape tuning of compressor airfoils is also carried out.