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Name: SHRI HARSH
USN: 23BTRAS040
Laser cutting
Laser cutting uses a powerful laser to cut materials
by vaporising them. It's widely used in
manufacturing and now by schools, businesses, and
hobbyists. The laser is directed by CNC, following a
pattern to cut the material with precision, leaving a
smooth finish.
In 1965, the first laser cutting machine drilled holes
in diamond dies, made by Western Electric
Engineering Research Center. In 1967, the British
used laser-assisted oxygen jet cutting for metals. By the early 1970s, this
method was used to cut titanium for aerospace. CO2 lasers were also used
to cut non-metals like textiles since they weren't strong enough for metals
back then.
Process
Laser cutting uses a focused
beam of light, often less than
0.0125 inches in diameter, to
cut materials with precision,
creating narrow kerf widths.
Before each cut, a pierce is
done to start from
somewhere other than the
edge. The beam, intensified by a lens or mirror, creates an intense laser beam
about 0.001 inches in size. Laser cutting offers advantages like easier work
holding, reduced contamination, and minimal heat-affected zones, making it
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suitable for cutting difficult materials. While it's more precise than plasma
cutting for thin metals, it may struggle with thicker materials, although newer,
high-power laser machines are closing the gap.
Types
There are three main
types of lasers used in
laser cutting: CO2,
Nd/Nd:YAG, and fiber
lasers. CO2 lasers are
versatile, used for
cutting, boring, and
engraving various
materials. Nd and Nd:YAG lasers are similar but differ in application; Nd is for
high energy but low repetition tasks, while Nd:YAG is for very high power
needs. CO2 lasers are commonly pumped using either DC or RF methods, with
RF being more popular due to fewer electrode issues. They're used for cutting
various materials. YAG lasers are for cutting metals and ceramics. Laser
generators and optics need cooling, typically using water circulated through a
chiller. Laser microjets combine water-jet guidance with laser cutting for debris
removal and cooling. Fiber lasers are solid-state lasers ideal for cutting
reflective metals, offering rapid processing, energy efficiency, reliability, and
minimal maintenance, making them suitable for highly productive operations.
Method
There are various laser cutting methods for different materials:
- Vaporization: The beam heats the material, creating a keyhole that
expands as vapor blows out, suitable for non melting materials like wood and
plastics. - Melt and blow: High-pressure gas blows molten material from the
cut, reducing power needs, mainly used for metals.
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- Thermal stress cracking: Focuses on brittle materials, creating cracks by
localised heating and expansion, commonly used for glass.
- Stealth dicing: Utilises a pulsed Nd:YAG laser to separate
microelectronic chips from silicon wafers.
- Reactive cutting: Uses a laser beam as an ignition source, similar to
oxygen torch cutting, ideal for cutting thick steel plates.
Tolerances and surface finish
Laser cutters have high precision, with an accuracy of 10 micrometers and
repeatability of 5 micrometers. The roughness of the cut surface varies with
sheet thickness, laser power, and cutting speed. For example, cutting low carbon
steel with 800 W power results in a roughness of 10 μm for 1 mm thickness, 20
μm for 3 mm, and 25 μm for 6 mm.
The process can hold tight
tolerances, often within 0.001
inch (0.025 mm), depending
on part geometry and machine
quality. Surface finish
typically ranges from 125 to
250 micro-inches (0.003 mm
to 0.006 mm).
Machine configurations
Industrial laser cutting machines come in three configurations: moving material,
hybrid, and flying optics systems.
- Moving material machines have a stationary cutting head and move the
material underneath it, which can be slower but requires fewer optics.
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- Hybrid lasers
move the table in one
axis and the head in the
other, offering a
constant beam path
length and potentially
simpler delivery
systems.
- Flying optics
lasers have a stationary
table and a moving
cutting head, making
them the fastest option
and suitable for thinner
materials.
These machines may
use pulsing technology for specific tasks, like piercing or creating small holes,
which can improve efficiency and quality.
Power consumption
The main downside of laser cutting is its high power consumption, with
industrial lasers typically ranging from 5% to 45% efficiency. The power usage
and efficiency can vary based on the laser type, output power, and operating
parameters. The amount of power needed for a job, called heat input, depends
on factors like material type, thickness, process used, and desired cutting speed.
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Production and cutting rates edit
The maximum cutting speed depends on factors like laser power, material
thickness, process type, and material properties. Industrial systems (1 kW or
more) can cut carbon steel from 0.51 to 13 mm thick. In many cases, lasers can
be up to thirty times faster than standard sawing methods.
