Dandan Zhao, Yugang Zhao
Water-jet guided laser (WJGL) technology has gained significant attention in precision manufacturing due to its extremely small heat-affected zone. However, laser-induced water breakdown severely constrains the achievable laser power and processing efficiency. This paper presents and validates an optical solution employing a custom-designed rotationally symmetric aspheric lens. The lens is designed to generate a sequence of discrete focal points distributed along the optical axis. This configuration maintains a high average laser power while suppressing the peak power density at each individual focus below the water breakdown threshold. Theoretical modeling and ray tracing simulations confirm the superior performance of the lens in creating a controllable multi-focal beam. Experimental results demonstrate that a WJGL system incorporating the six-focus aspheric lens operates stably at 350 W. This represents a 300 W increase compared to the conventional spherical lens, which had a stable operating power limit of approximately 50 W within this experimental system. In microgroove machining experiments on NiTi alloy, the new system achieved an approximately 3.5-fold increase in groove depth and a 2.7-fold reduction in taper angle. This study provides a practical and effective beam shaping strategy to overcome the fundamental power limitation in WJGL technology.