3-D simulation model for gas-assisted laser cutting

To date the numerical simulation of gas-assisted laser cutting has successfully evaded rigorous treatment, mainly due to the complexity of the process, and the intrinsic highly dynamic behaviour of the melt pool and the presence of a shield gas jet. Contrary to the usual approach of adjusting simulation aims to fit the constraints of available hardware, the authors have utilised state-of-the-art parallel computing to tackle the problem in a comprehensive manner. This paper describes a full 3-D numerical model that includes an assist gas simulation for pressures up to and exceeding 18 bar, evaporation of the melt (using the kinetic theory approach), flow patterns in the melt/film pool and thermal stresses in the substrate. It also resolves the physical domain down to the micro-scale. Initial results are outlined and the current limits of and costs involved with using contemporary HPC platforms for enabling this software are identified.