Modeling and analysis of the visualized gas-assisted laser cutting flow from both conical and supersonic nozzles

A coaxial high-pressure gas jet is normally used to assist and enhance laser cutting quality and capability. However, the gas nozzles are mostly of conical type causing the deterioration of the dynamic characteristics of the exit jet. In this research, the effect of both nozzle type and nozzle dimensions on the uniformity and behavior of the exit jet has been investigated. A total of three different supersonic nozzles have been designed in accordance to gas dynamics theory and manufactured using wire electrical discharge machining (WEDM). The exit jet patterns from these supersonic nozzles and a reference conical nozzle have been numerically modeled and compared with the experimental observations made through Schlieren visualization. The experimental results are found to match and hence validate the simulations. It is concluded that the exit jet from the supersonic nozzle is marked by uniformity, better dynamic characteristics, and longer effective exit jet length compared with conical nozzle.