Numerical Simulation and Validation of Laser Polishing of Alumina Ceramic Surface

Abstract

Laser polishing is a noncontact and efficient processing method for surface treatment of different materials. It removes surface material and improves its quality by means of a laser beam that acts directly on the surface of the material. The material surface roughness is a major criterion that evaluates the polishing effect when alumina ceramics are polished by a laser. In this study, the effects of three factors, namely, laser power, scanning speed, and pulse frequency, on the surface roughness were investigated through orthogonal tests. The optimum polishing parameters were obtained through a comparison of the experimental results. Compared to the initial surface roughness (Ra = 1.624 μm), the roughness of the polished surface was reduced to Ra = 0.549 μm. A transient two-dimensional model was established by the COMSOL Multiphysics 5.5, and the flow condition of the material inside the molten pool of laser-polished alumina ceramics and the surface morphology of the smoothing process were investigated by utilizing the optimal polishing parameters obtained from the experiments. The simulation results showed that in the process of laser polishing, the fluid inside the molten pool flowed from the peaks to the valleys under the action of capillary force, and the inside of the molten pool tended to be smoothened gradually. In order to verify the correctness of the numerical model, the surface profile at the same position on the material surface was compared, and the results showed that the maximum error between the numerical simulation and the experimental results was 17.8%.