Laser irradiation method for high-efficiency pulsed laser milling integrated die/mold machining: effects of laser-tracking irradiation on laser milling accuracy

In small and precision die and mold making, small-diameter end mills are often used through rough to finish machining processes. However, higher-efficiency machining technology in die and mold manufacturing is needed because shorter delivery time has become essential in recent years. On the other hand, the demand for dies and molds made of difficult-to-cut materials such as cemented carbide and fine ceramics has increased. Therefore, the authors were motivated to apply a laser process because lasers can remove work independently of its mechanical properties. The authors proposed a novel process for high-efficiency die and mold machining. The process integrates laser milling for rough processing and cutting with micro-end-mill tools for finishing. In the present paper, some experiments were carried out to clarify the effects of a laser-tracking irradiation method for laser-milling quality in deep milling of a hardened die steel workpiece. As a result, it was found that the laser-tracking irradiation provided higher-accuracy laser milling while maintaining process efficiency.