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Laser cutting system

Daniel Connolly
Anton Vorsteveld
Jared Wall
Oliver Williams
Yuan Yuan
Background
 Laser cutting has been used in industry since
the 1970's.
 The first common application was for sign-
making, mainly cutting acrylic.
 It is now a significant process in every
manufacturing economy.
Introduction
 Laser cutting is a technology that uses a
laser to cut precise patterns in most all types
of materials such as metal, ceramic ,paper
and so on.
Introduction
 There are two types of lasers used for
cutting:
 the gaseous CO2 laser
 the solid-state Nd:YAG laser.
Applications
 Wood
 Paper
 Leather
 Glass
 Ceramic
 Metal
Benefits
 The flexibility and precision cutting of
simple or complex parts;
 A non contact cut which means no marks or
contamination of the material;
 A high quality cut with no extra finishing
required;
 The ability to cut almost any material.
Drawbacks
 Material limitations (including crystalline
and reflective materials)
 Producing a piercing hole that can make the
pattern design more difficult.
 Reflected laser light can present a safety
hazard
 The cost of laser cutting machine is much
higher than other cutting processes
Economics of Laser Cutters
High Initial Costs, some machines $300,000 +
Protective glass, gas nozzles, dust and particle
filters need replacement
High use of cutting gasses 500-2000 L/H of O2
and/or N2 (.36 $/L)
Economics of Laser Cutters
Economics of Laser Cutters

*Assumes 1000 L/H consumption of gas, and .36 $/L


Economics of Laser Cutters
¨ Efficient use of Laser Cutters is very
material and application dependent
¨ Initial startup costs are high, but the larger
cost is the gas used to expel the material out
of the cut
¨ Creates very precise cuts with little to no
finishing work required
Components of System
 Control Unit (CNC program)
 Power supply (120 or 240 v)
 Workpiece positioning table
 may be fixed or move in up to 2 directions
 May contain fastening devices
 scrap removal system
 Optics Unit (focusing unit)
 mirrors, focusing lens,
 Fasteners
 Gas/debris removal system
Optical Unit
 Mirrors direct the beam from the source
down to the lens
 the lens then focuses the beam into the
desired geometry
 finally the assist gas is added to remove the
molten metal

www.osaka-gu.ac.jp www.cncmachines.us
Process

www.ebteccorp.com

www.matrixmetalcraft.com
Science
 The Beam
 .0875-.5 inches from the source
 ~.001 inch at the workpiece
 Many factors are material and thickness
dependent
 focal length, beam intensity, reed rate, cut with
(kerf), cut time, machine configuration
 Types of cut
 Vaporization cutting, Melt and Blow, Thermal
stress cracking, Burning Stabilized
Capabilities
 Materials
 Steel, Titanium, Paper, Wood, Leather, Wax,
Plastic, Fabric
 Easily cuts .5 inch stainless steel
 Limitations
 Reflective materials, highly conductive
 Many applications
Safety Hazards
 Contact with hot workpiece
 Hand/eye contact with beam
 Inhalation of fumes
 Smoke, Fumes, dust particles have
environmental risks
Machine Types
 Moving Material
 Positioning table moves in x-y plane
 Moving Optics
 Optical unit moves in x-y plane
 Hybrid
 Material moves in x, Optics move in y
Examples
 Hobby shop
 Small production runs
 Used for prototyping and hobbies
 Generally use a Moving Optics configuration
 Connected to fume hood for ventilation
 May be home made

www.germes-online.com http://nilno.com/laser_intro/system.html
http://www.youtube.com/watch?v=80-ZIWDNfIE

Examples
 Production Machine
 Medium to large production runs
 Used for producing production components
 Can be one of all 3 configurations
 Connected to fume hood for ventilation
 Contain production line facilitators
www.cupplesjandj.com

news.thomasnet.com
www.alibaba.com
Processes and Practices
¨ Laser Cutting Results
¡ Majority of applications are in 2D
¡ Extreme precision can be achieved
¡ Capable of providing high tolerances and
providing high quality surface finishes
¨ Results on the Material
¡ May affect hardness
¡ Possible change in grain size
¡ Narrow heat-affected zone
Processes and Practices
¨ Laser Applications
¡ Laser Welding
ú More accurate, reliable and fast than traditional
welding methods
¡ Laser Marking
ú Similarly accurate, reliable and fast in comparison
to traditional marking methods
Processes and Practices
¨ Current Uses of Laser Cutting Systems
¡ Primarily 2D Systems
¡ Either melts, burns, or vaporizes away material
¡ Used to cut flat-sheet metal and
piping/structural materials
Processes and Practices
¨ 3D Laser Cutting Applications
¡ The future of laser cutting
Processes and Practices
¨ About 3D Laser Cutters
¡ 6-axis rotary head to allow beveled and mitered
cuts
¡ Capable of cutting round, square, channel, angle
and other structural shapes
¡ Up to ¾” cut thickness
¡ Industries Served
ú Automotive, industrial, electrical, constructions
and aerospace
Pace Makers
A Case Study
 Trumpf Lasers
 Specializes in Medical Equipment
 Laser Welding, Cutting, Marking
Pace Makers
A Case Study
Pace Makers
A Case Study
 Utilizes laser cutting, welding, marking.
Pace Makers
A Case Study
 Nearly Seamless Markings
Pace Makers
A Case Study
Conclusion
 There are many useful applications and uses
for Laser Cutting in the current
manufacturing market
 Many new innovations are on their way and
new uses for this versatile cutting process
are cropping up each year
 The future of Laser cutting has a bright
future, so don’t forget your welding mask
Questions for the class
 Have any of you ever used or seen a Laser Cutting
Machine in use?
 Could Laser cutting ever completely substitute for
other cutting machines?
 What are the limitations with respect to what we
are covering in class right now?
 What future applications can you see Laser Cutting
to be useful for?
 Where on a car assembly line could Laser Cutting
improve quality and production times?
 Could you use laser cutting to reduce the safety
risks on a production floor?
 What role could Laser cutting perform in a job
shop?

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