Development of a local three-dimensional numerical simulation model for the laser forming process of aluminium components

The laser beam forming (LBF) process uses the energy of relatively high-powered lasers to cause permanent deformations of components, through the local introduction of thermal stresses. LBF of aluminium material is a process, complex and sensitive, due to the complicated physical phenomena taking place during laser processing. Therefore, definition of optimal process parameters, such as laser power and processing velocity, which will result to desired bending patterns, as well as investigation of forming limits of various components require significant experimental effort. Herein, numerical simulation of LBF process is used to provide partial solution to the problem, by developing a local Finite Element simulation model, capable to predict temperature fields and deformation shapes of laser beam-treated aluminium specimens. The numerical algorithm is based on a non-linear three-dimensional transient thermal–structural analysis, temperature-dependent thermal and mechanical material properties and a laser beam heat flux model. The developed model is validated through the comparison of numerically predicted distribution of temperatures and bending angles to corresponding experimental data of single and multiple laser beam passes. The validated model is then used to define optimal process parameters for the laser forming process of aluminium panels.