LASER POLISHING

Seminar Report

Submitted in partial fulfillment of the requirements for

the award of the Diploma in

Automobile Engineering

Submitted by:

NITHIN KRISHNAN
2101051233

DEPARTMENT OF AUTOMOBILE ENGINEERING

GOVERNMENT POLYTECHNIC COLLEGE ATTINGAL

November 2023
 DEPARTMENT OF AUTOMOBILE ENGINEERING

GOVT. POLYTECHNIC COLLEGE ATTINGAL

2023

CERTIFICATE

This is to certify that the seminar report titled “ LASER POLISHING”

being submitted by, Roll No. 2101051233, in partial fulfillment of the
requirements for the award of the Diploma in Automobile Engineering, is a
bonafide record of the seminar presented by NITHIN KRISHNAN at Govt.
Polytechnic College, Attingal.

Sajikumar S Premjith P.
Faculty-in-Charge Head of Department
 DECLARATION

I undersigned, hereby declare that the seminar report titled “LASER POLISHING”
submitted in partial fulfillment of the requirements for the award of diploma in Automobile
Engineering by State Board of Technical Education, Kerala, is a bonafide record of
seminar presented by me in Department of Automobile Engineering, Govt. Polytechnic
College, Attingal. This report has not previously formed the basis for the award of any
degree, diploma, or similar title of any other university.

NITHIN KRISHNAN

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 ACKNOWLEDGEMENTS

The satisfaction that accompanies the successful completion of any task would not
be complete without mentioning the people who have helped me to make it possible.

I express my gratitude to MR. SAJIL A, the Principal of polytechnic college

ATTINGAL and MR. PREMJITH P, the Head of Department of Automobile
Engineering, for providing with the best facilities and atmosphere for the completion
of this seminar.

I am grateful to Mr. SAJIKUMAR S, Lecturer and seminar Guide, for there

supervision. I also take this opportunity to thank all other staff members of
Automobile Engineering Department for their help and support.

Finally, this seminar would have not been possible without the confidence,
endurance, and support of my family. My family has always been a source of
inspiration and acknowledgement.

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 ABSTRACT

Surface quality and aesthetics play a crucial role in the automotive industry, impacting not
only a vehicle's appearance but also its overall performance. Laser polishing, a cutting-edge
surface finishing technique, has gained significant attention in recent years. This seminar
abstract delves into the fascinating world of laser polishing in the context of automobile
engineering.

The seminar will explore the principles, processes, and applications of laser polishing,
highlighting its potential to revolutionize the automotive manufacturing sector. Laser polishing
offers several advantages, such as precise material removal, reduced production time, and
enhanced surface finish, all of which contribute to improved fuel efficiency, aerodynamics, and
corrosion resistance in vehicles.

Moreover, this seminar will showcase real-world examples of laser polishing implementation
in automobile engineering, including its impact on components like engine parts, chassis, and
body panels. We will also discuss the challenges and future prospects of laser polishing,
considering factors like cost, environmental sustainability, and material compatibility.

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 INDEX

1) INTRODUCTION
2) WORKING OF LASER POLISHING
3) METHODS OF OPERATION
4) WORKING OF DUAL BEAM LASER MACHINE
5) APPLICATIONS OF LASER POLISHING
6) ADVANTAGES OF LASER POLISHING
7) LIMITATIONS OF LASER POLISHING
8) CONCLUSION

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 INTRODUCTION

Laser polishing is an advanced technique used to improve the surface finish of various
materials. It involves the use of laser energy to remove or melt the surface layer of a material,
resulting in a smoother and more polished surface. This seminar report aims to provide a
detailed overview of laser polishing, including its principles, applications, advantages, and
limitations.
Principles of Laser Polishing
Laser polishing works based on the principle of selective material removal or melting. A high-
energy laser beam is focused on the surface of the material, which causes the uppermost layer to
heat up rapidly. This localized heating results in the melting or vaporization of the material,
effectively removing any surface imperfections such as roughness or irregularities.
The process of laser polishing can be controlled by adjusting various parameters, including laser
power, scanning speed, beam diameter, and pulse duration. These parameters determine the
amount of material to be removed or melted, as well as the overall surface quality achieved.

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 WORKING OF LASER POLISHING

The working principle of laser polishing revolves around the use of high-intensity laser beams
to heat and melt the surface of a material. When the laser beam is directed onto the material, it is
absorbed, converting into intense thermal energy. This localized heating causes the material's
surface to rapidly melt and vaporize, effectively eliminating imperfections and irregularities. As
the material becomes molten, it naturally flows and redistributes, smoothing out roughness and
defects. Laser polishing is highly precise and controllable, allowing it to target specific areas
and intricate geometries. After the surface has been sufficiently heated and polished, the
material cools and re- solidifies, resulting in a smoother and more refined surface. Importantly,
laser polishing removes only a minimal amount of material, preserving the workpiece's
dimensions and providing a polished surface with reduced roughness and improved reflectivity.

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 METHODS OFOPERATION

There are two different methods of operations used in laser polishing

 MACRO POLISHING
 MICRO POLISHING

MACRO POLISHING

Macro polishing is a material surface finishing process that aims to enhance the surface
quality of a workpiece, particularly by removing macroscopic defects, irregularities, and
imperfections. Unlike micro polishing, which focuses on achieving sub-micron level
smoothness, macro polishing is concerned with addressing larger-scale flaws, such as scratches,
gouges, or rough surfaces, which are more visible to the naked eye. This method is commonly
used in various industrial sectors, including automotive, aerospace, and manufacturing, where a
high-quality surface finish is essential for both functional and aesthetic purposes.

The process of macro polishing involves the use of abrasive materials and mechanical or
chemical means to level, smooth, and refine the surface of a work piece. Common abrasive

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materials include grinding wheels, abrasive belts, or abrasive compounds, which are applied
with grinding machines, belt sanders, or other similar equipment. These abrasive materials
effectively remove excess material from the workpiece’s surface, gradually reducing
irregularities and defects.

Macro polishing operations are often conducted in multiple stages or passes, starting with
more aggressive abrasives to remove large defects and gradually transitioning to finer abrasives
for a smoother finish. The choice of abrasive material and the specific equipment used depend
on the type of material being polished, the initial condition of the surface, and the desired
surface finish. The process may also involve the use of coolants or lubricants to control heat and
prevent material buildup.

The outcome of macro polishing is a work piece with an improved surface quality, reduced
roughness, and enhanced visual appearance. This is particularly important in applications where
aesthetics, such as in consumer products or automotive components, are as critical as functional
performance. Moreover, the removal of macroscopic defects can contribute to the longevity and
reliability of the material or component. Overall, macro polishing plays a vital role in achieving
the desired surface finish in various industrial and manufacturing processes.

MICRO POLISHING

Micro polishing is a precision surface finishing process that is designed to improve the
surface quality of materials at a microscopic level. Unlike macro polishing, which primarily
targets larger- scale imperfections and defects, micro polishing focuses on achieving an
exceptionally smooth and uniform surface finish at the sub-micron level. This process is
employed in a wide range of industries, including optics, electronics, medical devices, and
precision engineering, where surface quality is a critical factor for both functionality and
aesthetics.

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 The micro polishing process typically involves the use of extremely fine abrasive materials,
such as diamond pastes or suspensions, to remove very thin layers of material from the
workpiece's surface. These abrasive materials are applied with specialized polishing equipment
that provides controlled and precise contact between the abrasive and the material. The action of
the abrasives serves to eliminate microscopic imperfections, such as scratches, pits, or waviness,
resulting in a mirror-like, defect-free surface.

Micro polishing is highly sensitive to factors such as pressure, abrasive particle size, and
contact time, which are carefully controlled to achieve the desired surface finish. Unlike macro
polishing, the removal of material during micro polishing is minimal, ensuring that the work
piece's dimensions are preserved. Additionally, the process is often carried out in a clean
environment to prevent contamination and maintain the integrity of the polished surface.

The benefits of micro polishing are significant, particularly in industries where precise
optics, electronics, or medical components are involved. The process yields ultra-smooth
surfaces with sub-micron roughness values, ensuring minimal friction, improved optical clarity,
and enhanced performance. Micro polishing is also essential for components like optical lenses,
semiconductors, and medical implants, where even the smallest imperfections can affect
functionality and quality. Overall, micro polishing plays a crucial role in achieving the high-
precision surface finishes required in advanced technology and manufacturing applications.

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 WORKING OF DUAL BEAM LASER MACHINE

A dual-beam laser polishing machine is an advanced and highly specialized tool used for
precision surface finishing of materials, particularly metals. Unlike conventional single-beam
laser systems, which use only one laser source for material surface treatment, dual-beam
machines incorporate two laser beams working in tandem. This dual-beam approach has a
transformative effect on the polishing process, making it particularly valuable in industries
where both exceptional surface quality and increased efficiency are critical, such as aerospace,
medical device manufacturing, and automotive engineering.

https://images.app.goo.gl/u2C9SkAwd6M8kAma6

The fundamental feature of a dual-beam laser polishing machine is the simultaneous

operation of two laser sources, each with distinct roles. One of the laser beams is typically more
powerful and serves the primary purpose of rapidly heating the material's surface. This intense
heating results in localized melting and removal of surface imperfections and roughness. It plays a
pivotal role in material removal and shaping, especially for larger defects or irregularities. This
first laser beam is akin to the heavy lifter in the process.

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Complementing this power beam is a second laser beam, which is usually lower in power but offers
additional control and finesse in the polishing process. While the first laser is removing material, the
second laser, with its lower energy, is fine-tuning the surface finish. This fine-tuning step is critical for
achieving the desired level of surface smoothness and defect reduction. The combined action of these
two laser beams working in harmony ensures a controlled and precise polishing process.

The key advantage of a dual-beam system is its ability to significantly enhance surface quality.
It achieves this by merging the material removal capabilities of the more powerful laser beam with the
surface refinement capabilities of the second laser beam. The result is an exceptionally smooth, defect-
free surface that meets the stringent quality requirements of critical applications. This technology is
ideal for components used in industries where a superior surface finish is paramount, such as
aerospace components, where reduced drag and increased fuel efficiency are crucial, or medical
implants, where biocompatibility and hygiene are vital.

Additionally, dual-beam laser polishing machines are often integrated with advanced control
and monitoring systems. These systems enable automation and real-time adjustments to optimize
the polishing process. Precise control over laser parameters and the ability to monitor the polishing
progress in real time contribute to the machine's efficiency and the consistently high quality of the
finished workpieces. In conclusion, dual-beam laser polishing machines represent a cutting-edge
solution for achieving top-tier surface finishes in industries where uncompromising quality and
performance are imperative.

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 APPLICATIONS OF LASER POLISHING

Laser polishing finds applications in various industries where a high-quality surface finish is
required. Some common applications include:

Manufacturing of precision components: Laser polishing can be used to enhance the

surface finish of components used in industries such as aerospace, automotive, and medical. It
can improve the performance and longevity of these components, leading to better overall
product quality.

Widely used in vehicles to smoothing surface of body and other components of vehicle.

Mold and die polishing: Laser polishing is an effective technique for polishing molds and
dies used in injection molding and other manufacturing processes. It can help eliminate defects
and increase the lifespan of these tools.

Jewelry and watch making: Laser polishing is widely used in the jewelry and watchmaking
industries to achieve a flawless and glossy finish on precious metals and gemstones.

Optical components: Laser polishing is crucial in the production of optical components like
lenses, mirrors, and prisms. It helps achieve the desired surface quality, which is essential for
optical performance.

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 ADVANTAGES OF LASER POLISHING

Laser polishing offers several advantages over traditional polishing methods: .

Precision: Laser polishing allows for precise control and adjustment of the polishing
parameters, resulting in a highly accurate and consistent surface finish.

Efficiency: Laser polishing can be a faster and more efficient process compared to
conventional polishing techniques, as it eliminates the need for manual labor and can polish
complex shapes and contours.

Versatility: Laser polishing can be applied to a wide range of materials, including metals,
ceramics, glass, and polymers.

Eco-friendly: Laser polishing is a non-contact process that produces minimal waste and
does not require the use of chemicals or abrasives, making it environmentally friendly.

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 LIMITATIONS OF LASER POLISHING

While laser polishing offers numerous advantages, it also has some limitations:

Material limitations: Laser polishing may not be suitable for all materials, especially those with
low melting points or those that are highly reflective.

Cost: The initial investment in laser polishing equipment can be high, making it less accessible for
small-scale operations.

Surface geometry limitations: Laser polishing may have limitations when it comes to polishing
complex geometries or surfaces with intricate features.

Safety considerations: Laser polishing involves the use of high-energy lasers, which require
proper safety measures to protect operators from potential hazards.

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 CONCLUSION

Laser polishing is a powerful technique that can significantly improve the surface quality of
various materials. Its precision, efficiency, and versatility make it a valuable tool in industries where
a high-quality surface finish is crucial. However, it's important to consider the limitations and safety
aspects when implementing laser polishing. As technology continues to advance, laser polishing is
expected to become even more widespread and accessible in various manufacturing sectors.

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