Investigation of laser stripping process parameters for insulation layers of large diameter aviation cables based on thermodynamic coupling

The rational selection of laser wire-stripping parameters is essential for achieving high processing quality and efficiency. This study investigates 8-AWG aviation cables insulated with polytetrafluoroethylene (PTFE) and employs a 405 nm diode laser to determine the optimal stripping conditions. A thermo-mechanically coupled finite-element model was established in COMSOL by integrating an interface-tracking scheme, an appropriate volumetric heat-source model, and realistic boundary conditions. Using a single-factor methodology, the effects of laser power, scanning speed, and processing time on stripping quality were systematically examined. The results indicate that increasing laser power significantly enhances stripping efficiency but simultaneously causes wider kerfs, larger heat-affected zones (HAZ), and greater thermal-expansion displacement. Higher scanning speeds effectively reduce kerf width, although potentially at the expense of processing efficiency, while moderate extensions of processing time lead to limited increases in cutting depth. By optimizing the combined parameters, stripping efficiency can be improved without compromising quality. Furthermore, a three-factor, three-level orthogonal experiment was conducted. Analysis of variance (ANOVA) revealed that laser power is the dominant factor affecting kerf depth and width, HAZ size, and thermal-expansion displacement. Through multi-objective optimization based on a binary satisfaction criterion, together with an energy-efficiency evaluation to quantify cutting performance, the optimal parameter set for PTFE insulation stripping of 8-AWG cables was determined to be a laser power of 0.9 W, a scanning speed of 3 r/s, and a processing time of 8 s. Finally, quantitative comparisons between simulation and experimental results under three identical parameter sets confirmed the model's predictive accuracy, providing a solid theoretical and practical foundation for high-quality, high-efficiency laser stripping of PTFE insulation on large-diameter aviation cables.