Integration of high power diode laser in machine tools: New processes for sophisticated products

The environment in manufacturing companies is characterised by constant pressure to develop innovative products and manufacturing techniques. New products can be launched effectively and economically on the market, only when all potential for optimisation is recognised and exploited at an early stage. Developments in materials technology are therefore resulting in the emergence of innovative advanced materials which have excellent characteristics to fit the requirements of specialised technical functions. However, the decision to use such materials in industrial applications is always accompanied by demands for the availability of corresponding machining processes which take account of the particular requirements of the material and which are, at the same time, economically efficient. The technical options which emerge from classical approaches to process optimisation are, however, frequently inadequate, particularly when the products in question are difficult to machine or cannot be manufactured using techniques currently applied in industry. Innovative manufacturing technologies such as "hybrid processes" open up completely new perspectives for an efficient production by the addition of extra energy sources to existent processes. With its compact dimensions and high efficiency, the high power diode laser in particular, provides new solutions for integration within machine tools. This contribution therefore outlines new approaches to hybrid processes on the basis of laser-assisted technologies. the potential of laser-assisted turning, milling and flow forming as well as the requirements imposed on machine concepts, which permit the application of each of these hybrid processes, will be discussed