Analytical Modeling of Laser

Moving Sources

Contains:
Heat flow equation
Analytic model in one dimensional heat flow
Heat source modeling
Point heat source
Line heat source
Plane heat source
Surface heat source
Finite difference formulation
Finite elements

Heat flow equation

For developing basic heat flow equation,
consider the differential element .
Heat balance in element is given by,

Heat in Heat out + Heat generated

= Heat accumulated
Heat in and out rates depends on conduction
and convection.

k 2T C p

T
C pU T = H
t

Heat flow through differential

element

Analytic model in one dimensional heat flow:

If the heat flow in only one direction and there is no convection or heat
generation, the basic equation becomes
where = diffusivity, t = time.
It is assumed that there is constant thermal properties, with no radiant
heat loss or melting, then the BC s are

The solution is,

Heat source modelling:

Introduction:
Why modeling?
1. Semi-quantitative understanding of the process mechanism for the
design of experiments.
2. Parametric understanding for control purpose. E.g. statistical charts.
3. Detailed understanding to analyse the precise process mechanisms
for the purpose of prediction, process improvement .
Types of heat sources:
Point heat source.
Line heat source.
Plane heat source. (e.g. circular , rectangular)

1.Instantaneous point heat source:

The differential equation for the conduction of heat in a stationary
medium assuming no convection or radiation, is
This is satisfied by the solution for infinite body,
dT '( x, y, z, t ) =

3
2

( x x ') 2 + ( y y ') 2 + ( z z ') 2

ex p [
]
4 a ( t t ')

3
2

( x x ') 2 + ( y y ') 2 + ( z z ') 2

ex p [
]
4 a ( t t ')

q
C (4 a ( t t '))

sem i in f in ite
dT '( x, y, z, t ) =

2 q

C (4 a ( t t '))

q = instantaneous heat generated, C = sp. heat capacity, = diffusivity,

= Density, t = time, K = thermal conductivity.
gives the temperature increment at position (x, y, z) and time t due to an
instantaneous heat source q applied at position (x, y, z) and time t.

Results:
1. When (x, y, z) = (0,0,0) and (x, y, z) = (0,0,0)
T = 473.3379
2. When (x, y, z) = (0.5,0.5,0) and (x, y, z) = (0,0,0)
T = 413.0811
3. When (x, y, z) = (2,2,0) and (x, y, z) = (0,0,0)
T = 53.5792
For temperature over entire surface
consider heat source at (0,0,0)
and workpiece have dimension
50 X 50. Temperature distribution
Is shown in figure.

2. Continuous point heat source in infinite body:

If the heat is liberated at the rate dQ= P.dt from t = t to t = t+ dt at the
point (x, y, z), the temperature at (x, y, z) at time t is found by
integrating above equation, and C = sp. heat capacity, = diffusivity,
= Density. From the point heat source solution,
q
C (4 a(t t '))

3
2

( x x ') 2 + ( y y ') 2 + ( z z ') 2

exp[
]
4a (t t ')

now integrating w. r. t. Time t from 0 to t.

where Q is in Watts. As
occurs given by

steady state temperature distribution

T=
4 k

Hx x'L2 + H y y'L2 + Hz z'L2

Moving point heat source in semi-infinite body

In moving coordinate system:

2 q

dT '( x, y, z, t ) =

C (4 a ( t t '))

3
2

( X x ') 2 + (Y y ') 2 + ( Z z ') 2

exp [
]
4 a ( t t ')

In fixed coordinate system:

dT '( x, y, z, t ) =

2 q

C (4 a ( t t '))

3
2

Note that

( x vt ' x ') 2 + ( y y ') 2 + ( z z ') 2

ex p [
]
4 a ( t t ')

q = Pdt '

Moving point heat source:

Consider point heat source P heat units per unit time moving with velocity v on semiinfinite body from time t= 0 to t= t. During a very short time heat released at the
surface is dQ = Pdt. This will result in infinitesimal rise in temperature at point (x, y, z)
at time t given by,
t '= t

dT '( x, y, z, t ) =

t '= 0

2 Pdt '

C (4 a ( t t '))

3
2

( x vt ' x ') 2 + ( y y ') 2 + ( z z ') 2

ex p [
]
4 a ( t t ')

The total rise in of the temperature can be obtained by

integrating from t=0 to t= t

Line heat source in infinite body:

Temperature for the line heat source can be obtained directly by integrating the solution of the
moving point source in the moving coordinate system.

Moving line source in moving coordinate:

Line source parallel to z-axis and passing through point (x , y). The temperature
obtained by integrating , where C = sp. heat capacity, = Density, K = thermal
conductivity. Here Ql = heat per unit length
For infinite body
q

dT ' ( x, y, z , t ) =

C (4 a (t t '))
dT ' ( x, y, t ) =

ql

C (4 a (t t '))

3
2

( X x ') 2 + (Y y ') 2 + ( Z z ') 2

exp[
]
4a (t t ')

3
2

( X x ') 2 + (Y y ') 2 + ( Z z ') 2

]dz
exp[
4a (t t ')

X= x-vt, Y=y and Z=z

Moving line heat source in fixed coordinates:

Fig. keyhole model (W. Steen)

Plane heat source:

Surface heat source:

Area (circular, rectangular heat source)
Applied on x-y plane.
Temperature depends on intensity.
Application: surface hardening,
surface cladding etc.

Gaussian moving circular heat source:

Gaussian heat source intensity

In moving coordinate system,

2 q

dT '( X ,Y , Z , t ) =

ex p [

C ( 4 a ( t t ')) 2

2dt '

dT ' =

C (4 a(t t '))

dT '(t ) =

3
2

( X x ') 2 + (Y y ')2 + ( Z z ') 2

I ( x ', y ')dx ' dy 'exp[
]
4a(t t ')

4 Pdt '

2 C (4 a (t t '))

dx ' dy 'exp[(

( X x ') 2 + (Y y ') 2 + ( Z z ') 2

]
4 a ( t t ')

3
2

2 x '2 + 2 y '2

x '2 2( X ) x '+ ( X ) 2 + y '2 2Yy '+ Y 2 + Z 2

+
)]
4a (t t ')

Moving heat source.

Where P = laser power, = beam radius, v = scanning velocity, a = diffusivity, t =time.

Rewriting the solution for fixed coordinate system,

Rewriting the solution for fixed coordinate

system,

4 Pdt '

dT '(t ) =
2

C (4 a(t t '))
4P
T T0 =
C 4 a

3
2

z2
2 4a(t t ')
2(( x vt ')2 + y 2 )
exp[ 2
]

2
+ 8a(t t ')
+ 8a(t t ')
4a(t t ')

t '= t

dt '(t t ') 0.5

2(( x vt ') 2 + y 2 )
z2
t '= 0 2 + 8 a (t t ') exp[ 2 + 8 a (t t ') 4 a (t t ') ]

Similarly circular heat source can be found

out.

Modeling Gaussian heat source:

Material and process parameters: for EN18 steel
Laser power = 1300W
Scanning velocity = 100/6 mm/sec
Interaction time = 0.18sec.
Beam Radius = 1.5mm
Temperature distribution X-Y plane

Diffusivity = 5.1mm^2/sec
Density = 0.000008 kg/mm^3
Sp. Heat capacity = 674 J/kg k

Temperature along X-Z plane.

Uniform intensity:
Uniform circular moving heat source:
In the Uniform heat source, Q is defined by the magnitude
q and the distribution parameter . The heat distribution, Q,
is given by,
Where A = *2
for circular heat source integrating with space variables,

dT ( t ) =

2 Pdt '
8 C 2 ( a ( t t '))

( X x ')
exp[
]dx '
4 a ( t t ')

3
2

2 x '2

2 x '2

Z2
exp[
]
4 a ( t t ')
(Y y ') 2
exp[
]dy '
4 a ( t t ')

Now final temperature equation is obtained by integrating with time from 0 to t,

Uniform rectangular moving heat source:

Rectangular heat source of dimension l < x < l and b < y < b i.e. for semi-infinite body
moving with constant velocity v from time t = 0 to t = t.
Heat intensity I is given by,
where A = 4*b*l
Integrating with the space variables,

d T (t ) =

2 Pdt '
4 b l C ( 4 a ( t t ') )

3
2

z2
exp[
]
4 a ( t t ')

( ( x v t ') x ') 2
( y y ') 2

e
x
p
[
]
d
x
'
e
x
p
[
]d y '
l

4 a ( t t ')
4 a ( t t ')
b

Results can be obtained by numerical integration with respect to time.

Comparison of Gaussian and uniform heat

source: for EN 18 steel

Results:
Fig. Comparison of
width/depth of hardened
zone[13]

No
1
2
3
4
5

Finite difference formulation:

Nodal points
Nodal network
Regular or irregular
Types - coarser
- fine

Temperature at time interval t

Finite Element Models

02/08/10

Thermal Modeling
Heat generated in workpiece due to cutting is small compared
to the heat generated by the laser
A scaled model (5mm x 2mm x 2mm) is used
The Gaussian distribution of laser power intensity Px,y is given
by:
2

2 Ptot
2r
Px , y = 2 exp 2
rb
rb

The average absorptivity of incident irradiation is determined

experimentally
Temperature dependent thermophysical properties are used

Mathematical Formulation
The 3-D transient heat conduction equation is given by,
T
k
x x

T
T
T T .

+
+
+
Q
=

c
+

c
V
k
k

p
p
y z z

t
x
y

Initial condition,
T(x, y, z, 0) = T0
Natural boundary condition on front face,
T
k
q + h(T T0 ) + (T 4 T04 ) = 0
n
T
k
q + he ( T T0 ) = 0
n
3
1.61
h
=
2
.
4

10

T
(Frewin et al., 1999)
where,
e

Mathematical Formulation
Average measured temperatures are used for boundary
conditions on remaining external surfaces
Half symmetry used at bottom face

qbottom = 0

Case Study- Thermal Model

1
ELEMENTS
MAT

NUM

Natural B.C. on front face

JUL 19 2006
14:52:01

Y
Z

Y
X

Z
Symmetry B.C. on bottom face

Mapped dense mesh (25 m x 12.5 m x 20m)

An 8 noded 3-D thermal element (Solid70) is used
Gaussian distribution of heat flux applied to a 5x5 element matrix
which sweeps the mesh on the front face

Temperature Simulation
1
NODAL SOLUTION
JUL 20 2006
10:37:08

STEP=41
SUB =10
TIME=6
TEMP
(AVG)
RSYS=0
SMN =150
SMX =1876

X
(Laser scan direction)

MX

150

533.653
341.827

917.307
725.48

1301
1109

1685
1493

1876

Simulated temperature distribution for H-13 steel (10 W laser power, 10

mm/min scan speed and 110 m spot size)