For the application of metal laser cutting machines, cutting quality is the first condition to be considered. Metal laser cutting machines with good cutting quality can create value for metal fabricators. Therefore, it is necessary to master the problems often encountered in the cutting process and their solutions.
Now let’s get down to brass tacks and talk about some typical quality defects and how to prevent them—because ain’t nobody has time for subpar cuts! And find the most suitable laser cutting machine in Baison.
Laser cutting in metal fabrication offers several advantages, including high precision, versatility, speed, and minimal heat-affected zone. Laser processing is widely used in industries such as manufacturing, automotive, aerospace, electronics, and more.
Understanding the types of laser cutting machines and the working principles of laser cutting can help in selecting the right equipment and optimizing the cutting process for specific applications.
There are several types of laser cutting machines, each designed to cut different materials and workpieces. The main types of laser cutting machines include CO2 lasers, fiber lasers, and neodymium-doped YAG lasers.
These machines use different laser powers of high quality cut through various materials, such as metal, plastic, and wood. The laser beam is focused through a lens to create a concentrated light signal that can accurately cut through the material surface.
CO2 Laser Cutting Machines: These machines use a carbon dioxide gas laser to generate the laser beam. CO2 laser cutters are versatile and can cut through a wide range of materials, including wood, acrylic, plastics, fabrics, leather, and some metals. They are commonly used in industries such as signage, packaging, and textiles.
Fiber Laser Cutting Machines: Fiber laser cutting machines use a solid-state laser source, typically a fiber optic cable, to generate the laser beam. Fiber lasers are highly efficient and are primarily used for cutting metals, such as stainless steel, mild steel, brass, and copper. They offer high cutting speeds and are commonly used in industries such as automotive, aerospace, and metal fabrication. The light signal is emitted through the focusing lens onto the workpiece.
YAG Laser Cutting Machines: YAG (yttrium-aluminum-garnet) lasers are solid-state lasers that use a crystal medium to generate the laser beam. YAG lasers are known for their high output power and are capable of cutting through thicker materials, such as metals, ceramics, and some plastics. They are commonly used in industries that require high precision and accuracy, such as jewelry making and electronics. The YAG laser’s ability to cut through thick steel and workpiece makes it ideal for industrial applications.
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Laser cutting is a precise and efficient process that utilizes a high-powered laser beam to cut through various materials. Here’s how it works.
Laser cutting is a technology that uses a focused laser beam to cut through materials. The laser beam is generated by a laser source and directed through a series of mirrors or fiber optics to the laser head. The laser head contains a lens that focuses the laser beam to a small spot size, increasing its intensity.
When the laser beam interacts with the workpiece, it heats and vaporizes or melts the material, creating a narrow cut. The focused laser beam provides high energy density, allowing for precise and controlled cutting. The movement of the cutting head, guided by CNC (Computer Numerical Control), determines the shape and light path of the cut.
Compared with other thermal cutting methods, laser cutting has many significant advantages. The following are specific advantages.
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Laser metal cutting is a widely used technique in various industries, offering precise results and increasing production efficiency. However, it is not without its challenges. The process can encounter several quality defects that may compromise the integrity of the final product.
Burrs are raised edges or rough surfaces that occur during laser cutting. They can affect the aesthetics and functionality of the cut parts. Burr formation can be caused by factors such as improper laser focus, excessive cutting speed, or inadequate assist gas pressure.
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Laser cutting generates heat, which can lead to a heat-affected zone around the cut edge. This zone may have altered material properties, such as increased hardness or reduced ductility, affecting the performance of the cut parts.
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Dross or slag refers to the molten material that solidifies on the bottom surface of the cut. Adherence to dross can affect the quality of the cut and may require additional post-cut cleaning.
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Laser cutting can sometimes result in rough or uneven edges, which can affect the aesthetics and functionality of the cut parts.
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Laser cutting utilizes powerful light to feed laser energy into the material, resulting in precise cuts. However, this process can sometimes lead to discoloration or oxidation on the cutting edge, impacting the overall appearance and surface quality of the parts.
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Inconsistent gas pressure can result in variations in the cutting process, leading to irregularities in the cut quality, such as taper or angle deviations.
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Laser cutting thin materials with high power can sometimes result in warping or distortion due to the intense heat input.
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Kerf, the width of the cutting slit made by the laser, is crucial for accurate dimensions and proper fitment of parts. A narrow kerf allows cut patterns to be nested as close as one beam diameter apart, an effective way to reduce scrap metal. Inconsistent kerf width can negatively impact the cutting surface and cutting seam. Therefore, it’s important to optimize the cutting speed to ensure precise results.
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Laser cutting has the power to cause re-solidification or re-melting of the material along the cut edges, leading to rough or uneven surfaces.
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Different materials may require specific gas compositions to achieve optimal cutting results. Using the wrong gas composition can lead to poor cut quality, increased dross formation, or excessive heat input.
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Nonnormal sparks during laser cutting of low carbon steel indicate poor cut quality and potential defects. To rectify this issue, several solutions can be implemented:
Insufficient shielding gas coverage on the cut metal surface may result in nonnormal sparks during laser tube cutting. Here are some solutions to address this issue and improve cutting speed.
By implementing these solutions, manufacturers can effectively address nonnormal spark issues when cutting low carbon steel and stainless steel using laser technology.
1. How do I prevent excessive heat from affecting my cuts?
Excessive heat during laser metal cutting can be prevented by using suitable cooling techniques such as air or water cooling systems. Optimizing laser power settings and controlling the speed of the cutting process helps manage heat generation.
2. How can I prevent tapering in my cuts?
Tapering, where the cut width varies along its length, can be mitigated by optimizing cutting parameters such as focal point position, cutting speed, and assist gas pressure. Ensuring proper alignment of the laser beam also helps maintain consistent cut quality.
3. Are there any precautions for cutting reflective metals?
When cutting reflective metals like aluminum or copper, it is essential to use appropriate wavelength lasers and specialized optics. Implementing a back reflection protection system further ensures safe and efficient cutting.
4. How can I avoid distortion in delicate materials?
Delicate materials prone to distortion during laser metal cutting can benefit from using lower power settings and slower cutting speeds. Employing a smaller focal laser spot size also aids in minimizing heat-affected zones and potential material deformation.
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Metal laser cutting is an extremely flexible manufacturing process that provides high-speed, high-quality cutting for parts used in a variety of applications.
To ensure high-quality laser metal cutting, it is crucial to address and prevent common defects that may arise during the process. By implementing effective prevention methods, you can enhance the overall cutting performance and achieve optimal results.
The important factor of cutting quality is the quality of the metal laser cutting machine itself, so you must choose a strong manufacturer when buying equipment. Baison Laser has nearly 20 years of experience in the laser cutting machine manufacturing industry. With strong technical strength, we have established a good reputation in the industry. Welcome to consult more details and get the application evaluation today!
When you’re in the laser business, you get a lot of questions. Below, we’ve answered 10 of our most frequently asked questions.
Yes. A properly outfitted CO2 laser can cut metal. We’ve developed a metal cutting option, which allows CO2 lasers to cut metals with relative ease. We’ve been doing it for years.
It depends. More specifically, it depends on three primary variables:
If you have a particular metal you’d like to discuss, you can always contact us to discuss the specifics of your material. We will help you determine how or if you’re able to use a CO2 laser cutter to process your desired thickness.
Another option is to send a piece of your material to us and we will cut it into a shape and send it back to you. Then, you can see the edge quality and cut quality for yourself to determine if it meets your standards. Click here if you’re interested in having us test your material on a Kern Laser System.
It depends. Laser cutting speeds depend on three primary variables:
For example, let’s look at how wattage impacts CO2 laser cutting speeds.
If you’re cutting ⅛” acrylic plastic on a 150W laser, it’s going to cut 3-4 inches per second. Now, if you take that same material and cut it on a 400W laser, it’s going to cut at about 6-7 inches per second.
Engraving speeds on Kern Laser systems are anywhere from 100 inches per second to 150 inches per second. These speeds are for surface engraving, which typically uses a lower power to mark the surface of a material.
3D engraving, which involves putting depth into a material, anywhere from 3/16” to 1/4″, has speeds that vary from 20 inches per second to 45 inches per second. 3D engraving speeds depend on the intricacy of the pattern.
The laser engraves at varying depths to create a 3D effect using grayscale. Our KCAM software is able to read 256 different shades of grey, and those shades tell the laser what depth to engrave to.
For example, if you drew a three-inch square and made half of it black and the other half light gray, the laser could engrave it at around 30-40 inches per second. The black part of the square would engrave much deeper into the wood than the light gray would.
Overall, operating a laser system is safe. Like all CNC equipment, when operating an open bed (Class 4) laser system eye protection is required. Always rely on your company’s LSO (laser safety officer) to determine the correct laser safety glasses. And remember, enclosed (Class 2) laser systems — like our FiberCELL and LaserCELL — do not require safety glasses.
No. This is an infrared radiant energy that is produced when operating the laser. It’s the same energy that is used in commercial and residential appliances like microwaves. It is a well-tested, very safe way of creating heat.
We design and build all of our systems in our factory here in Wadena, Minnesota. It’s been this way since 1982. Everything in the system is American-made.
Pipe rotary, k-vision, metal cutting, Z12 monument package, advanced safety package, fume scrubbers and PhotoGrav software.
To discuss available options, please contact us.
Yes. We have a technical support team capable of helping with any issue you have. When you call Kern Laser Systems during business hours, you will be greeted by a live receptionist. We pride ourselves on providing excellent customer service. Please check out our testimonials to hear from our customers about their experiences with tech support.