Studying the Effects of Process Parameters on Bending Angle and Edge Effects in Laser Bending Process of Perforated Sheets

Conventional bending processes for perforated sheets using steel dies often result in undesirable deformation of the holes along the bend line. In contrast, the laser bending process presents a suitable alternative for effectively bending these sheets. This study investigates the laser bending process of perforated sheets through experimental tests and numerical simulations, employing a finite element model for the simulations. The effects of process variables, including laser power, scanning speed, laser beam diameter, and the number of holes along the irradiating path, on the output parameters (bending angle and edge effects), are examined. The finite element simulation and experimental measurements demonstrate good agreement. Results indicate that the bending angle of laser-bent perforated sheets increases with higher laser power, larger laser beam diameter, reduced scanning speed, and fewer holes in the irradiation path. Furthermore, the lateral deformation of the free edges (edge effect) increases with greater laser power, reduced scanning speed, larger laser beam diameter, and higher number of holes in the irradiation path. The edge effect is influenced by the temperature gradient along the irradiation path; higher laser power generates elevated local temperatures and increased cooling rates, whereas higher scanning speed leads to a more uniform temperature distribution in the sheet.