A quality improvement method for complex component fine manufacturing based on terminal laser beam deflection compensation

The multi-axis laser manufacturing equipment is a piece of standard equipment suitable for complex components with hard and brittle material. The laser beam direction inevitably deviates from the coordinate axis of equipment due to the location of laser and optical parts, leading to component’s substrate over-cutting. This paper proposes a compensation method for the laser beam deflection to enhance the accuracy of the laser manufacturing. The deflection measurement was achieved by image and point cloud processing. The proposed method scans the point cloud model and fits the geometric feature to realize the orientation of the laser collimator relative to the equipment. The error of laser beam deflection calculates by the orientation of collimator and the spatial geometric relationship of the displacement and the laser trajectory. An error compensation model is constructed to compensate for dynamic error in the whole motion range during the calculation of equipment motion. The effectiveness of this method is verified through laser beam measurement, compensation and laser manufacturing for a complex component. The results show that the proposed method improves the processing accuracy (91.6 μm versus 316.6 μm) by data statistics.