Progress in tridimensional (3d) laser forming of stainless steel sheets

Achievement of complex shapes with high dimensional accuracy and precision by forming process is a demanding challenge for scientists and practitioners. Available technologies are numerous, with laser forming being progressively emerging because of limited springback, lack of molds and sophisticated auxiliary equipments. However, laser forming finds limited applications, especially when forming of tridimensional (3d) complex shapes is required. In this case, cost savings are often counterbalanced by the need for troublesome forming strategies. Therefore, traditional alternatives based on mechanical devices are usually preferred to laser systems. In the present work, 3d laser forming of stainless steel sheets by high power diode laser is investigated. In particular, the set of scanning patterns to form domes from flat blanks by simple and easy-to-manage radial paths alone was found. Numerous 3d items were also processed by diode laser to manufacture a number of complex shapes with high flexibility and limited efforts to modify the auxiliary forming equipment. Based on the experimental results and analytical data, the high power diode laser was found able to form arbitrary 3d shapes through the implementation of tailored laser scanning patterns and appropriate settings of the operational parameters.