The Theory of Laser Materials Processing: Heat and Mass Transfer in Modern Technology
The Theory of Laser Materials Processing: Heat and Mass Transfer in Modern Technology
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Theuseoflasersinmaterialsprocessinghasbecomewidespreadinrecent years,sothatanunderstandingofthenatureofheatandmasstransferin thisbranchofmoderntechnologyisofincreasingimportance. Theaimofthe authorsofthisbookistoconcentrateonthephysicalprocesses;thesecanbe developedfromamathematicalpointofview,orfromdirectexperimental- derivedobservation. Thetwoapproachesarecomplementary;eachcanprovide insightsandthesynthesisofthetwocanleadtoaverypowerfulunderstanding oftheprocessesinvolved. Mathematicalmodellingofphysicalprocesseshas hadanimportantroletoplayinthedevelopmentoftechnologyoverthe centuriesandparticularlysointhelastonehundredand?ftyyearsorso. Itcanbearguedthatitismoreimportanttodaythaneverbeforesincethe availabilityofhigh-speedcomputersallowsaccuratenumericalsimulationof industrialprocessesatafractionofthecostofthecorrespondingexperiments. Thisisoneaspectofmathematicalmodelling,highpro?leandmuchvalued, butitisnottheonlyone. Inthepastmathematicalmodellinghadtorelyonqualitativeinves- gation,veryspecialanalyticalsolutions,orinaccurateandtime-consuming calculationsperformedwithlittleinthewayoftabulatedormechanical assistance. Logtablesandsliderulesarestillrememberedbypeopleworking today,thoughtherearesurelyfewwhoregrettheirdisappearance. Thevalueanddistinctivefunctionofmethodsbasedontheanalytical approachisnowbecomingmuchclearer,nowthattheyarenolongerexpected toproducedetailedimitationsofwhathappensinrealexperimentsofind- trialprocesses,afunctionnowful?lledmostlybynumericalmethods,c- sideredbelow. Theemphasistodayisontheirabilitytocon?rmandextend ourunderstandingofthebasicphysicalmechanismsinvolvedintheprocesses of interest. These are essential for any intelligent use of numerical simulation. Theargumentaboutthevalueofteachingpeoplehowtodoarithmetic themselveswithouttheaidofacalculatorseemstobepassingintohistory, vi Preface butitisanimportantoneandprovidesasimpleanalogy. Ifsomeonedoes nothaveafeelingfornumbersandthewayarithmeticworks,theywillalltoo easilyfailtospotanerrorproducedbyamachine. Computersarenotinfallible -andneitherarethosewhobuildorprogramthem. Computersarenow takingonlessmundanemathematicaltasksandthesamecontroversiesare appearinginconnectionwithalgebraicmanipulation. Equally,andwitheven greaterpenaltiesintermsofcostintheeventoferrors,thesameconsiderations applytonumericalsimulationofmajorindustrialprocesses. Awarenessofthe analyticalsolutionscanbeinvaluableindistinguishingtherightfromthe wrong,i. e. forthepractitionertounderstandthebasisofthework,andto haveanideaofthekindsofoutcomesthatareplausible-andtorecognise thosewhicharenot. Thephrase mathematicalmodelling is,however,ambiguous,perhaps morenowthanithaseverbeen. Thereisanenormousamountofworkdone todayonsimulationbasedontheuseofverypowerfulcomputerprograms, anditisquitecorrectlyreferredtoasmathematicalmodelling. Theprograms aresometimesconstructedin-housebutareusuallycommercialpackages. This isanentirelyvalidapproachwithspeci?c(generallycommercial)objectives. Ingeneraltherearetwouses. Thedominantobjectiveisnumericalagreement withaparticularexperimentinthe?rstinstance,leadingtopredictivec- mercialuseinthesecondinstance. Thesecondobjectiveistheclari?cation ofphysicalmechanisms,aimedatthegenerationofunderstandingofcomplex interconnectedprocesses,ratherthantheexactreproductionofaparticular experiment. Itissometimesoverlookedthat,withsu?cientcare,anum- icalapproachisequallyvalidintheinvestigationofphysicalfundamentals. Numericalsimulationisnotacentraltopicofthisbook,butbecauseofits crucialimportancetoeachofthetwousestowhichnumericalmodellingcan beput,itisvitalthatthecomputationalbasisoftheworkshouldbec- pletelysound. Inaddition,thelevelofprocessdetailwhichcanbeconsidered bythenumericalapproachusuallyexceedswhatispossiblewiththeanaly- calapproachsigni?cantly,leavinglittlechoicebuttoreverttothenumerical treatmentwheninvestigatingtheinterconnectionsbetweenprocesses. Itis forthesereasonsthatthebookconcludeswithachapteroncomprehensive numericalsimulation. Inmanyways,theapproachadoptedhereiscomplementarytothemore phenomenologicalapproach. Itisalwaysimportantina?eldwhichhasvery directindustrialapplicationstobearinmindhowtechniquessuchasthose describedherewillbeused,butitisessentialnottolosesightofthef- damentals. Thereareserioussafetyimplications;therearecostimplications; therearemoralimplications;thereareconsiderationsoftheappropriateness ofthetechnologytotheapplicationunderconsideration. Aproperrespectfor alltheserequiresanunderstandingofthefundamentals. Wearealltoowellawarethatthisbookdoeslittlemorethanscratch thesurfaceoftheproblemsinvolvedinafundamentalunderstandingofthese phenomena. Ifwehaveprovidedideasandinformationthatcauseothersto Preface vii testthemexperimentallyorintellectually,agreewiththemordisputethem vigorously,anddevelopthemfurther,wewillconsiderthatwehaveachieved ouraim. Colchester April,2008 JohnDowden Contents 1MathematicsinLaserProcessing JohnDowden…1 1. 1 MathematicsanditsApplication…1 1. 2 FormulationinTermsofPartialDi?erentialEquations…3 1. 2. 1 LengthScales…3 1. 2. 2 ConservationEquationsandtheirGeneralisations…4 1. 2. 3 GoverningEquationsofGeneralised ConservationType…7 1. 2. 4 Gauss'is,however,ambiguous,perhaps morenowthanithaseverbeen. Thereisanenormousamountofworkdone todayonsimulationbasedontheuseofverypowerfulcomputerprograms, anditisquitecorrectlyreferredtoasmathematicalmodelling. Theprograms aresometimesconstructedin-housebutareusuallycommercialpackages. This isanentirelyvalidapproachwithspeci?c(generallycommercial)objectives. Ingeneraltherearetwouses. Thedominantobjectiveisnumericalagreement withaparticularexperimentinthe?rstinstance,leadingtopredictivec- mercialuseinthesecondinstance. Thesecondobjectiveistheclari?cation ofphysicalmechanisms,aimedatthegenerationofunderstandingofcomplex interconnectedprocesses,ratherthantheexactreproductionofaparticular experiment. Itissometimesoverlookedthat,withsu?cientcare,anum- icalapproachisequallyvalidintheinvestigationofphysicalfundamentals. Numericalsimulationisnotacentraltopicofthisbook,butbecauseofits crucialimportancetoeachofthetwousestowhichnumericalmodellingcan beput,itisvitalthatthecomputationalbasisoftheworkshouldbec- pletelysound. Inaddition,thelevelofprocessdetailwhichcanbeconsidered bythenumericalapproachusuallyexceedswhatispossiblewiththeanaly- calapproachsigni?cantly,leavinglittlechoicebuttoreverttothenumerical treatmentwheninvestigatingtheinterconnectionsbetweenprocesses. Itis forthesereasonsthatthebookconcludeswithachapteroncomprehensive numericalsimulation. Inmanyways,theapproachadoptedhereiscomplementarytothemore phenomenologicalapproach. Itisalwaysimportantina?eldwhichhasvery directindustrialapplicationstobearinmindhowtechniquessuchasthose describedherewillbeused,butitisessentialnottolosesightofthef- damentals. Thereareserioussafetyimplications;therearecostimplications; therearemoralimplications;thereareconsiderationsoftheappropriateness ofthetechnologytotheapplicationunderconsideration. Aproperrespectfor alltheserequiresanunderstandingofthefundamentals. Wearealltoowellawarethatthisbookdoeslittlemorethanscratch thesurfaceoftheproblemsinvolvedinafundamentalunderstandingofthese phenomena. Ifwehaveprovidedideasandinformationthatcauseothersto Preface vii testthemexperimentallyorintellectually,agreewiththemordisputethem vigorously,anddevelopthemfurther,wewillconsiderthatwehaveachieved ouraim. Colchester April,2008 JohnDowden Contents 1MathematicsinLaserProcessing JohnDowden…1 1. 1 MathematicsanditsApplication…1 1. 2 FormulationinTermsofPartialDi?erentialEquations…3 1. 2. 1 LengthScales…3 1. 2. 2 ConservationEquationsandtheirGeneralisations…4 1. 2. 3 GoverningEquationsofGeneralised ConservationType…7 1. 2. 4 Gauss'Theuseoflasersinmaterialsprocessinghasbecomewidespreadinrecent years,sothatanunderstandingofthenatureofheatandmasstransferin thisbranchofmoderntechnologyisofincreasingimportance. Theaimofthe authorsofthisbookistoconcentrateonthephysicalprocesses;thesecanbe developedfromamathematicalpointofview,orfromdirectexperimental- derivedobservation. Thetwoapproachesarecomplementary;eachcanprovide insightsandthesynthesisofthetwocanleadtoaverypowerfulunderstanding oftheprocessesinvolved. Mathematicalmodellingofphysicalprocesseshas hadanimportantroletoplayinthedevelopmentoftechnologyoverthe centuriesandparticularlysointhelastonehundredand?ftyyearsorso. Itcanbearguedthatitismoreimportanttodaythaneverbeforesincethe availabilityofhigh-speedcomputersallowsaccuratenumericalsimulationof industrialprocessesatafractionofthecostofthecorrespondingexperiments. Thisisoneaspectofmathematicalmodelling,highpro?leandmuchvalued, butitisnottheonlyone. Inthepastmathematicalmodellinghadtorelyonqualitativeinves- gation,veryspecialanalyticalsolutions,orinaccurateandtime-consuming calculationsperformedwithlittleinthewayoftabulatedormechanical assistance. Logtablesandsliderulesarestillrememberedbypeopleworking today,thoughtherearesurelyfewwhoregrettheirdisappearance. Thevalueanddistinctivefunctionofmethodsbasedontheanalytical approachisnowbecomingmuchclearer,nowthattheyarenolongerexpected toproducedetailedimitationsofwhathappensinrealexperimentsofind- trialprocesses,afunctionnowful?lledmostlybynumericalmethods,c- sideredbelow. Theemphasistodayisontheirabilitytocon?rmandextend ourunderstandingofthebasicphysicalmechanismsinvolvedintheprocesses of interest. These are essential for any intelligent use of numerical simulation. Theargumentaboutthevalueofteachingpeoplehowtodoarithmetic themselveswithouttheaidofacalculatorseemstobepassingintohistory, vi Preface butitisanimportantoneandprovidesasimpleanalogy. Ifsomeonedoes nothaveafeelingfornumbersandthewayarithmeticworks,theywillalltoo easilyfailtospotanerrorproducedbyamachine. Computersarenotinfallible -andneitherarethosewhobuildorprogramthem. Computersarenow takingonlessmundanemathematicaltasksandthesamecontroversiesare appearinginconnectionwithalgebraicmanipulation. Equally,andwitheven greaterpenaltiesintermsofcostintheeventoferrors,thesameconsiderations applytonumericalsimulationofmajorindustrialprocesses. Awarenessofthe analyticalsolutionscanbeinvaluableindistinguishingtherightfromthe wrong,i. e. forthepractitionertounderstandthebasisofthework,andto haveanideaofthekindsofoutcomesthatareplausible-andtorecognise thosewhicharenot. Thephrase mathematicalmodelling is,however,ambiguous,perhaps morenowthanithaseverbeen. Thereisanenormousamountofworkdone todayonsimulationbasedontheuseofverypowerfulcomputerprograms, anditisquitecorrectlyreferredtoasmathematicalmodelling. Theprograms aresometimesconstructedin-housebutareusuallycommercialpackages. This isanentirelyvalidapproachwithspeci?c(generallycommercial)objectives. Ingeneraltherearetwouses. Thedominantobjectiveisnumericalagreement withaparticularexperimentinthe?rstinstance,leadingtopredictivec- mercialuseinthesecondinstance. Thesecondobjectiveistheclari?cation ofphysicalmechanisms,aimedatthegenerationofunderstandingofcomplex interconnectedprocesses,ratherthantheexactreproductionofaparticular experiment. Itissometimesoverlookedthat,withsu?cientcare,anum- icalapproachisequallyvalidintheinvestigationofphysicalfundamentals. Numericalsimulationisnotacentraltopicofthisbook,butbecauseofits crucialimportancetoeachofthetwousestowhichnumericalmodellingcan beput,itisvitalthatthecomputationalbasisoftheworkshouldbec- pletelysound. Inaddition,thelevelofprocessdetailwhichcanbeconsidered bythenumericalapproachusuallyexceedswhatispossiblewiththeanaly- calapproachsigni?cantly,leavinglittlechoicebuttoreverttothenumerical treatmentwheninvestigatingtheinterconnectionsbetweenprocesses. Itis forthesereasonsthatthebookconcludeswithachapteroncomprehensive numericalsimulation. Inmanyways,theapproachadoptedhereiscomplementarytothemore phenomenologicalapproach. Itisalwaysimportantina?eldwhichhasvery directindustrialapplicationstobearinmindhowtechniquessuchasthose describedherewillbeused,butitisessentialnottolosesightofthef- damentals. Thereareserioussafetyimplications;therearecostimplications; therearemoralimplications;thereareconsiderationsoftheappropriateness ofthetechnologytotheapplicationunderconsideration. Aproperrespectfor alltheserequiresanunderstandingofthefundamentals. Wearealltoowellawarethatthisbookdoeslittlemorethanscratch thesurfaceoftheproblemsinvolvedinafundamentalunderstandingofthese phenomena. Ifwehaveprovidedideasandinformationthatcauseothersto Preface vii testthemexperimentallyorintellectually,agreewiththemordisputethem vigorously,anddevelopthemfurther,wewillconsiderthatwehaveachieved ouraim. Colchester April,2008 JohnDowden Contents 1MathematicsinLaserProcessing JohnDowden…1 1. 1 MathematicsanditsApplication…1 1. 2 FormulationinTermsofPartialDi?erentialEquations…3 1. 2. 1 LengthScales…3 1. 2. 2 ConservationEquationsandtheirGeneralisations…4 1. 2. 3 GoverningEquationsofGeneralised ConservationType…7 1. 2. 4 Gauss'sLaw…10 1. 3 BoundaryandInterfaceConditions…11 1. 3. 1 GeneralisedConservationConditions…11 1. 3. 2 TheKinematicConditioninFluidDynamics…13 1. 4 Fick'sLaws…15 1. 5 Electromagnetism…15 1. 5. 1 Maxwell'sEquations…15 1. 5. 2 Ohm'sLaw…18 References…19 2SimulationofLaserCutting WolfgangSchulz,MarkusNiessen,UrsEppelt,KerstinKowalick…21 2. 1 Introduction…22 2. 1. 1 PhysicalPhenomenaandExperimentalObservation…23 2. 2 MathematicalFormulationandAnalysis…26 2. 2. 1 TheOne-PhaseProblem…29 2. 2. 2 TheTwo-PhaseProblem…42 2. 2. 3 Three-PhaseProblem…51 2. 3 Outlook…64 2. 4 Acknowledgements…65 References…65 x Contents 3KeyholeWelding:TheSolidandLiquidPhases AlexanderKaplan…71 3. 1 HeatGenerationandHeatTransfer…71 3. 1. 1 Absorption…
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