Technology for laser thermoforming of thin-walled metal structural elements
DOI:
https://doi.org/10.17721/1812-5409.2025/2.14Keywords:
thin-wall metal elements, laser thermoforming, thermoviscoplasticity theory, thermomechanical model, finite element simulation, residual stress-strain stateAbstract
The article investigates the thermoforming of thin-walled metal structural elements using pulsed laser irradiation with a physically nonlinear thermoviscoplastic finite element model. The research focuses on the deformation mechanisms caused by transient thermal loads and their impact on the geometric accuracy of the molded parts. Simulation shows that pulsed laser irradiation creates localized thermal stresses and residual plastic deformations, which in turn cause controlled bending of thin metal sheets without the need for external dies or mechanical tools.
Numerical analysis demonstrates that the temperature-dependent viscoplastic properties of alloys play a decisive role in determining the efficiency of deformation and the stability of the resulting geometry. This article proposes a numerical model for simulating the laser thermoforming (LTF) process. It is based on the thermodynamically consistent theory of coupled thermoviscoplasticity. It is shown that it is suitable for modeling LTF for thin-walled metal structural elements. Within this model, the problem formulation consists of the Cauchy equation, the equations of motion, and the heat conduction equation, as well as mechanical and thermal boundary conditions and initial conditions. A generalized model of physically nonlinear temperature- dependent thermoviscoplasticity is used to describe the behavior of the material. Spatial discretization of the axisymmetric problem of laser pulse loading of the disk is performed using the finite element method. The unsteady process of LTF of the deformed disk configuration is modeled. The final profile of the disk is obtained as a result of the thermally induced state of residual stresses and deformations caused by rapid heating and subsequent gradual cooling of the material in the laser irradiation area. The results confirm that laser thermoforming allows localized shaping of thin-walled parts with reduced material waste, lower energy consumption, and higher flexibility compared to conventional forming methods. In particular, the modeling results align with experimental trends reported in the literature, where bending angle control, curvature reversal, and multi-pass strategies are feasible for both aerospace-scale panels and micro-electromechanical system (MEMS) components.
Pages of the article in the issue: 101 - 104
Language of the article: English
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Copyright (c) 2025 Prof. Yaroslav A. Zhuk, Arash Soleiman Fallah
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