Abstract
Electrical discharge machining (EDM) and laser cutting are thermal separation processes widely used in shaping and contour cutting applications. However, there are gaps in understanding the dynamics of the process, especially issues related to cut quality. This work describes the advances in fundamental physical modeling and process monitoring of laser cutting, as well as time varying processes such as contour cutting. The onset of evaporation and the increase of capillary forces are the two physical phenomena relevant to the build-up of adherent dross. The dynamic model predicts a modulation frequency for the laser power that leads to almost complete suppression of adherent dross in contour cutting.