Mathematical modeling and CFD analysis with experimental investigation of the geometry of the grooves created with CO2 laser on the polycarbonate plate

Abstract The primary goal of this study is to present a mathematical model that forecasts the quality of the final product to be obtained in laser material processing. Two stages of testing have been conducted to assess the dependability of the proposed mathematical model: an experimental phase and a CFD analytical phase. Heat dispersion mechanisms on and within the material are the foundation for the suggested mathematical model. A CO 2 laser was used to create micro-grooves in the polycarbonate sheet. Top and cross-sectional images of the laser-created grooves were taken using a high-resolution optical microscope. The groove geometry was measured from the images obtained. The dimensions of the ablation, melting, and glass transition zones obtained from the measurements and the thermal constants of the material were used in the mathematical modeling. The Fourier finite difference method was used to model the temperature distribution along the line on the polycarbonate surface. The lateral temperature distribution on the surface of the material and the vertical temperature distribution towards the depth of the material were studied separately. The error rates between the proposed mathematical model and the experimental results are between 3.24 and 8.44%. Since the experimental results are in good agreement with the proposed model, it can be said that the proposed mathematical model is reliable. In addition, the temperature distributions both in the lateral direction and perpendicular to the material were modeled using CFD (Computational Fluid Dynamics). The sources of the differences between the ignition, melting, and glass transition temperatures obtained from the CFD analysis and the real temperature values were discussed.