@article{SommerGoetzendorferEsenetal.2021, author = {Sommer, David and G{\"o}tzendorfer, Babette and Esen, Cemal and Hellmann, Ralf}, title = {Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling}, series = {Design and Post Processing for Metal Additive Manufacturing}, volume = {14}, journal = {Design and Post Processing for Metal Additive Manufacturing}, number = {19}, doi = {https://doi.org/10.3390/ma14195753}, pages = {1 -- 23}, year = {2021}, abstract = {We report on a comprehensive study to evaluate fundamental properties of a hybrid manufacturing approach, combining selective laser melting and high speed milling, and to characterize typical geometrical features and conclude on a catalogue of design rules. As for any additive manufacturing approach, the understanding of the machine properties and the process behaviour as well as such a selection guide is of upmost importance to foster the implementation of new machining concepts and support design engineers. Geometrical accuracy between digitally designed and physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line projection. In particular, we identify design rules for numerous basic geometric elements like walls, cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build direction, and holes of different shape, respectively, as being manufactured by the hybrid approach and compare them to sole selective laser melting. While the cutting tool defines the manufacturability of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2 µm. Thus, the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this particular promising hybrid approach by demonstrating an injection mold with a conformal cooling for a charge socket for an electro mobile}, subject = {Selektives Laserschmelzen}, language = {en} } @article{SommerPapeEsenetal.2022, author = {Sommer, David and Pape, Dominik and Esen, Cemal and Hellmann, Ralf}, title = {Tool Wear and Milling Characteristics for Hybrid Additive Manufacturing Combining Laser Powder Bed Fusion and In Situ High-Speed Milling}, series = {Ultra-Precision Manufacturing Technology for Difficult-to-Machine Materials}, volume = {15}, journal = {Ultra-Precision Manufacturing Technology for Difficult-to-Machine Materials}, number = {3}, doi = {https://doi.org/10.3390/ma15031236}, pages = {1 -- 13}, year = {2022}, abstract = {We report on milling and tool wear characteristics of hybrid additive manufacturing comprising laser powder bed fusion and in situ high-speed milling, a particular process in which the cutter mills inside the powder bed without any cooling lubricant being applicable. Flank wear is found to be the dominant wear characteristic with its temporal evolution over utilization period revealing the typical s-shaped dependence. The flank wear land width is measured by microscopy and correlated to the achievable surface roughness of milled 3D-printed parts, showing that for flank wear levels up to 100 μm a superior surface roughness below 3 μm is accessible for hybrid additive manufacturing. Further, based on this correlation recommended tool, life scenarios can be deduced. In addition, by optimizing the finishing tool start position and the number of afore-built layers, the milling process is improved with respect to the maximum millable angle for undercut surfaces of 3D-printed parts to 30° for the roughing process and to 40° for the entire machining process including finishing}, subject = {Hochgeschwindigkeitsfr{\"a}sen}, language = {de} } @inproceedings{FranzRothRungetal.2021, author = {Franz, Daniel and Roth, Gian-Luca and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {Superimposed beam deflection using acousto-optical deflectors in combination with a galvanometer scanner}, series = {Lasers in Manufacturing - LiM 2021}, booktitle = {Lasers in Manufacturing - LiM 2021}, year = {2021}, subject = {Galvanometer}, language = {en} } @inproceedings{SchwarzRungEsenetal.2020, author = {Schwarz, Simon and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {Current results on laser-based production of complex optics in glass}, series = {10. Wetzlarer Herbsttagung "Moderne Optikfertigung", 29. - 30. September 2020, Wetzlar}, booktitle = {10. Wetzlarer Herbsttagung "Moderne Optikfertigung", 29. - 30. September 2020, Wetzlar}, year = {2020}, subject = {Laserbearbeitung}, language = {en} } @inproceedings{SchwarzRungEsenetal.2020, author = {Schwarz, Simon and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {UKP-Prozess mit anschließendem CO2-Laserpolieren zur Fertigung komplexer Optiken}, series = {10. Workshop Laserbearbeitung von Glaswerkstoffen}, booktitle = {10. Workshop Laserbearbeitung von Glaswerkstoffen}, year = {2020}, subject = {Linse}, language = {en} } @article{SchleierAdelmannEsenetal.2021, author = {Schleier, Max and Adelmann, Benedikt and Esen, Cemal and Glatzel, Uwe and Hellmann, Ralf}, title = {Development and evaluation of an image processing algorithm for monitoring fiber laser fusion cutting by a high-speed camera}, series = {Journal of Laser Applications}, volume = {2021}, journal = {Journal of Laser Applications}, number = {33}, doi = {10.2351/7.0000391}, pages = {032004 -- 032004}, year = {2021}, subject = {Faserlaser}, language = {en} } @article{ZettlRungEsenetal.2021, author = {Zettl, Julian and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {Tangential Laser Turning of Fused Silica Using Ultra-short Laser Pulses}, series = {Journal of Laser Micro/Nanoengineering}, volume = {16}, journal = {Journal of Laser Micro/Nanoengineering}, number = {1}, doi = {10.2961/jlmn.2021.01.2008}, pages = {42 -- 46}, year = {2021}, abstract = {Laser turning with ultra-short laser pulses provides the possibility of manufacturing rotationally symmetric geometries, even of hard to machine materials as fused silica, down to a micrometer scale. In this laser micro machining approach, the laser beam is oriented perpendicularly to the rotational axis and tangentially to the material, whereas the target geometry is realized by moving the constantly rotating specimen according to the specified geometry under the focused laser spot. Due to the fric-tion-less laser ablation it is possible to realize a turning process in fused silica without the use of a contacting tool and therefore without causing mechanical tensions in the work piece. The processing head focuses the laser to a calculated spot size of 18 μm in diameter and the applied processing gas pressure assists in removing the ablated material. In this study, femto-second laser turning of fused silica with a diameter of 3.7 mm is investigated. The influence of the applied pulse energy is stated and the use of a trepanning optic during the turning process is characterized. Furthermore, compre-hensive parameter studies in order to optimize roughness and to find the maximum achievable abla-tion rate are shown. Limited by the mechanical speed of the rotational axis, the highest feasible abla-tion rate is 19.5 mm³/min. A roughness of Ra 0.65 μm are demonstrated.}, subject = {Laserbearbeitung}, language = {en} } @article{ZettlKlarRungetal.2021, author = {Zettl, Julian and Klar, Maximilian and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {Laser turning with ultrashort laser pulses}, series = {Journal of Manufacturing Processes}, volume = {2021}, journal = {Journal of Manufacturing Processes}, number = {68}, doi = {10.1016/j.jmapro.2021.06.025}, pages = {1562 -- 1568}, year = {2021}, abstract = {We report on a comprehensive micromachining study of rotationally symmetric parts using femtosecond laser. A laser turning process with tangential impingement of the laser radiation complemented by a trepanning optics is implemented as to accomplish a true laser lathe micromachining approach. With the objective of optimized ablation rate and reduced surface roughness, the influence of pulse energy, feed rate, trepanning diameter and angular beam incidence, respectively, is investigated for processing stellite rods. We find the smallest feasible feature sizes of 8.5 μm in diameter and smoothest surfaces with an arithmetic average of the roughness profile as low as 0.18 μm. The surface roughness, however, appears to be limited by the occurrence of laser induced periodic surface structures provoked by the femtosecond laser radiation. Furthermore, the variation of the fluence in accordance to the incidence on a curved surface is discussed and the heat input into the material is examined through a longitudinal cross section.}, subject = {Ultrakurzer Lichtimpuls}, language = {en} } @article{SchwarzRungEsenetal.2021, author = {Schwarz, Simon and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {Enhanced ablation efficiency using GHz bursts in micromachining fused silica}, series = {Optics Letters}, volume = {46}, journal = {Optics Letters}, number = {2}, pages = {282 -- 285}, year = {2021}, subject = {Fr{\"a}sen}, language = {de} } @article{SchwarzGoetzendorferRungetal.2021, author = {Schwarz, Simon and G{\"o}tzendorfer, Babette and Rung, Stefan and Esen, Cemal and Hellmann, Ralf}, title = {Compact Beam Homogenizer Module with Laser-Fabricated Lens-Arrays}, series = {applied sciences}, volume = {2021}, journal = {applied sciences}, number = {11}, pages = {1018 -- 1018}, year = {2021}, subject = {Femtosekundenlaser}, language = {en} }