Posted By: Andy Kamashian | Posted On: June 16, 2023
5 Ways To Improve Laser Cutting
Laser cutting has revolutionized the manufacturing industry by providing precise and efficient cutting solutions. With Fiber Laser Technology the machines prices have plummeted putting this technology in reach of everyone. However, there is always room for improvement to enhance the quality and productivity of laser cutting processes. In this article, we explore five key areas that can significantly improve laser cutting: material quality, programming/nesting, power, assist/cutting gases, and controlling heat. By addressing these aspects, manufacturers can optimize their laser cutting operations, leading to superior results and increased efficiency.
The quality of the material being cut has a direct impact on the laser cutting process and thus your success at it. Inferior material quality can result in uneven cuts, excessive burrs, and reduced precision. To improve your performance and cut quality, improve your material quality:
a) Select high-quality materials: Choose materials that have uniform composition, minimal impurities, and consistent thickness. This ensures smoother cutting and reduces the risk of defects.
b) Surface preparation: Properly clean and prepare the material's surface before cutting. Remove any contaminants, such as oil, dust, or rust, as they can affect the cutting process and compromise the quality of the cut.
Programming/Nesting:Efficient programming and nesting of parts play a crucial role in optimizing laser cutting operations. Programming involves creating a set of instructions for the laser cutter, while nesting focuses on arranging parts in the most efficient manner on the material sheet. Maximizing material usage and thus decreasing costs, starts at programming. Consider the following techniques to improve programming and nesting:
a) CAD/CAM software: Utilize advanced computer-aided design (CAD) and computer-aided manufacturing (CAM) software to generate accurate cutting paths and optimize material utilization. That parts basic, but using the right system that knows the process limitations of laser is important as it can through programming avoid problematic issues like tip ups through tabbing. These tools enable precise control over the cutting process, minimizing waste and maximizing productivity.
b) Nesting algorithms: Implement intelligent nesting algorithms that analyze the geometry of the parts to be cut and optimize their arrangement on the material sheet. Efficient nesting reduces scrap material and improves cutting speed, resulting in cost savings and enhanced productivity. They know when to put parts inside the drops of other parts, which orientation to run and which side of the line the beam needs to be on. They can also quickly identiofy lasers meant for etching or scribing vs layers that are meant to be cut cleanly.
Power:The power of the laser used for cutting is a critical factor in achieving desirable results. Typically you want to use all the available power and speed from your laser, however using the recommended power is best for cut quality, accuracy and consumable life. The right power settings combined with the right gas mixture improve the power aspect of laser cutting but there are other factors as well to get the right power to the material:
a) Regular maintenance: Ensure the laser cutting machine is properly maintained and calibrated. Periodic maintenance, including cleaning the optics and checking beam alignment, helps maintain optimal power output and cutting performance.
b) Power modulation: Adjust the laser power according to the specific material and thickness being cut. Fine-tuning the power settings helps avoid excessive heating or insufficient cutting, leading to improved precision and reduced material distortion.
Assist/Cutting Gases:The choice and proper use of assist/cutting gases significantly influence laser cutting quality and speed. Assist gases help remove molten/vaporized material from the cutting area, protect the surrounding material from excess heat and protect the lens from debris. Here's how to optimize their use:
a) Gas selection: Choose the appropriate assist gas based on the material being cut. Different materials have varying requirements, and using the right gas enhances the cutting process. Common gases used include oxygen, nitrogen, and compressed air.
b) Gas pressure and flow rate: Optimize the gas pressure (PSI or BAR) and flow rate (CFM) for the specific material and thickness. Adequate gas pressure and flow rate ensure efficient removal of molten material, resulting in cleaner cuts and reduced post-processing requirements.
Controlling Heat:Heat control is vital in laser cutting to prevent material deformation, warping, or unwanted thermal effects. Proper heat management ensures consistent cutting quality and minimizes the need for secondary operations. Consider the following measures:
a) Stagger Cut: Staggering the cut across the sheet reduces heat build up in any given area of the sheet reducing the chance for material warpage and costly damage to your laser head.
b) Cooling systems: Check and make sure your using the recommended and effective cooling systems, to cool the cutting head which can lead to the laser going out of focus and the cut quality deteriorating.
b) Pulse duration and frequency: Adjust the pulse duration and frequency of the laser to optimize heat input. Shorter pulses and higher frequencies minimize heat-affected zones, leading to cleaner cuts and reduced thermal distortion.
Enhancing laser cutting processes requires a holistic approach that addresses various aspects such as material quality, programming/nesting, power, assist/cutting gases, and controlling heat. By focusing on these areas, manufacturers like you can achieve higher precision, improved productivity, and superior cutting quality. Investing in high-quality materials, utilizing advanced software, optimizing power settings and assist gases, as well as controlling heat, will result in more efficient and cost-effective laser cutting operations, positioning companies for success in the ever-evolving manufacturing industry.
If your running a laser or looking for the latest technology Southern Fabricating Machinery Sales has the right system for your manufacturing needs and your budget. Also remember we can finance any machine, new or used, that we offer to make your next laser even more productive.