The art of laser cutting

From: Subject: The art of laser cutting Date: Mon, 2 Jan 2006 14:05:36 +0100 MIME-Version: 1.0 Content-Type: multipart/related; type="text/html"; boundary="----=_NextPart_000_00EB_01C60FA5.9AA4CD30" X-MimeOLE: Produced By Microsoft MimeOLE V6.00.2900.2670 This is a multi-part message in MIME format. ------=_NextPart_000_00EB_01C60FA5.9AA4CD30 Content-Type: text/html; charset="utf-8" Content-Transfer-Encoding: quoted-printable Content-Location: http://www.thefabricator.com/LaserCutting/LaserCutting_Article.cfm?ID=529 =EF=BB=BF The art of laser cutting Cutting = Laser=20 Cutting
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Cutting > Laser=20 Cutting Tech Cell > Laser=20 Cutting Article List > Laser Cutting Article

The FABRICATOR=C2=AE

The art of laser = cutting
Will recent advancements meet future=20 challenges?

By Johannes Ulrich, Contributing=20 Writer
March 27, = 2003

Laser cutting continues to grow in = popularity with=20 sheet metal fabricators. With developments in speed, cutting = quality, and manufacturing economy in laser cutting, today's = manufacturers have more options than ever before from which = to=20 choose the optimal manufacturing method for their specific=20 applications.

On modern laser cutting machines, most = of the=20 internal functions are automated. Focus point is changed = remotely=20 via a cutting database or technology table. Assist gas = change and=20 pressure are system-controlled as well. The numerically = controlled=20 cutting database has taken over almost all of the = operational=20 commands, leaving simple functions such as nozzle or focus = lens=20 alignment or change to the operators.

Higher laser powers of 2,500 watts and = more have=20 advanced the technology too. These high powers can process = thicker=20 metal, but the real advantage has been increased feed rates = on thin=20 metals. Cutting speeds on metal have increased almost = threefold with=20 the use of inert gas.

Ultrafast flying-optic laser cutting = machines,=20 introduced in the late 1990s, and punch-laser combinations = have been=20 gaining ground. Ultrafast laser cutting systems that use=20 linear-drive technology offer fast part processing time in=20 combination with accuracy and reduced setup times. With the=20 integration of several work stages in the punching unit, the = manufacturing of a variety of components becomes possible at = a lower=20 cost per component on punch-laser combination machines.

Figure=20 1
Laser-punch combination machines perform a = variety of=20 punching operations and CO₂ laser cutting = in one=20 system.

As a result of the harsh economic = climate of the=20 past two years, the need for higher volumes of the same part = numbers=20 is disappearing. Today many manufacturers are looking closer = at=20 lasers and combined fabricating systems to meet low-run = production=20 while having the flexibility to accommodate any market=20 requirement.

However, it's important to understand = how the=20 features of the current technology will fare into the = future.=20 Evaluating which features will become obsolete and costly in = the=20 years to come is the real challenge.

Punch-Laser Combination Machines

Punch-laser combination machines have = been used in=20 the industry since the 1980s. These machines perform a = variety of=20 punching operations and CO₂ laser cutting with up = to=20 3,500 W in one system (see Figure 1).

Figure=20 2
Laser-punch combination machines integrate = punching,=20 nibbling, forming, marking, contouring, bending, = tapping, and=20 laser cutting operations in a single unit, giving them = the=20 ability to produce complex and varied=20 parts.

The punching operation can be generated = either by=20 a hydraulic system=E2=80=94with the possibility for more = than 1,000 hits on=20 1-millimeter axis movement-or by a servomotor-driven = mechanism that=20 combines electrical servo technology and mechanical power=20 transmission. Another option is the recently introduced = linear-drive=20 motor technology, which allows the punch-laser to work as = fast as a=20 three-axis, high-speed laser system.

These combination machines can perform = punching,=20 nibbling, forming, marking, contouring, bending, and tapping = operations (see Figure 2). Typically, the laser is = used for=20 outside part contouring and special inner contours to = prevent=20 nibbling marks and sharp edges and to reduce material = handling, the=20 number of operations, and the need for special tools.

Modular extensions to the system include = loading-unloading equipment (see Figure 3) and true = multiaxis=20 part sorting or stacking robots. The laser-cut parts are = guided=20 outside the working area via trap doors and conveyor = systems. From=20 this point or even straight from the cutting position, a = multiaxis=20 sorting and stacking robot can transfer the parts to their=20 programmed sorting addresses.

High-speed Laser Cutting Systems

Figure=20 3
Modular extensions to the system include=20 loading-unloading equipment and multiaxis part sorting = or=20 stacking robots.

High-speed laser cutting machines can = process=20 components of various contours, thicknesses, and materials. = They can=20 cut 1-mm-thick mild steel at 20 meters per minute or faster, = and a=20 3,500-W laser can cut mild steel up to 20 mm thick (see = Figure=20 4). To achieve these high speeds, laser cutting systems = have=20 been developed that dramatically reduce assist gas = consumption, and=20 part processing speed has increased, neither of which lowers = part=20 quality.

Acceleration recently has increased with = the=20 introduction of linear-drive technology (see Figure = 5). New,=20 rigid machines had to be developed to support positioning = speeds up=20 to 300 m per minute and acceleration of more than 20 m per = second=20 squared while maintaining path accuracy.

Figure 5
A=20 3,500-W laser can cut mild steel up to 20 mm=20 thick.

Figure=20 4
Digitally controlled linear-drive motor = technology=20 has created a new generation of high-speed laser = cutting=20 systems.

With new drive and speed developments, = as well as=20 more material handling devices such as loading and unloading = units,=20 the laser processing time for a complete sheet has been = reduced=20 significantly.

Laser Automation

The biggest trend in laser cutting over = the last=20 10 years has been toward automation. Some companies have = justified=20 the purchase of laser automation by saying it reduces labor=20 requirements; however, this is just one element. The = consistent=20 operation of an automated cell, especially with a laser at = the heart=20 of it, offers flexibility to the manufacturer.

With automation, reaction time to = customer demands=20 is minimal. If the part can be drawn, then it can be = processed and=20 put into a production schedule with no tooling inventory to = manage=20 or pallets to prepare for processing.

More and more companies are implementing = lean=20 manufacturing strategies to minimize wasted movement and=20 overproduction of parts, in turn reducing inventories. An = automated=20 laser cell can help companies achieve these goals.

The Right Direction

While the basic elements of laser = cutting have not=20 changed in the last 20 years, continuous improvements have = been made=20 to each portion of the processing window. The future of any=20 technology, however, depends on how that technology serves = the user.=20 Integrating new laser technology into laser cutting systems = or=20 combination machines seems to be a move in the right = direction to=20 meet future market demands.

Johannes Ulrich is a manager of the = laser=20 division of Finn-Power International Inc., 710 Remington = Road,=20 Schaumburg, IL 60173, 847-885-3200, fax 847-885-9692, mailto:rjk@finnpower.com?subject=3DThe=20 art of laser cutting, http://www.finnpower.com/.=20 Finn-Power manufactures hydraulic and servo-electric turret = punch=20 presses, flexible manufacturing cells and systems, lasers, = press=20 brakes and robotic press brakes, automated benders, and = other sheet=20 metal fabrication = equipment.

<= /TD>

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