Experimental study on dynamic and precise machining of 3D ceramic components with free-form surfaces by short-pulse laser

The machining of complex 3D ceramic components is always challenging due to the irregular curvature of the blade surface and extremely low machinability. In this study, a ceramic propeller component with a size of several tens of millimeters was efficiently machined (MRR = 5.2–8.2 mm3/min) using a direct laser milling method. During the milling of curved surfaces, geometric discrete design and planning of the curved scanning path were proposed, relying on the dynamic control of the laser beam and its focal spot. A nonuniform offset model was designed for compensation milling according to the step effect at the curvature turning point of the surface, resulting in the improvement of the curved profile and its surface roughness (∼3.4 μm). The distinctive machining strategy and fabrication method in this study offer new opportunities for direct machining of hard or brittle materials with complex curved surfaces, and can provide reliable technical support for expanding the application of hard-to-machine materials in high-end manufacturing and extreme environments.