Many different types of companies make use of laser cutting because of how accurate and flexible it is for cutting and engraving materials. It makes precise cuts or engravings using a concentrated beam of powerful light energy, usually produced by a laser.
Along the specified cutting path, the focused light energy from the laser beam melts, burns, or vaporises the material as it passes over its surface. Cutting complex forms or designs from a variety of materials with little waste is now possible because to laser cutting's unmatched precision.
Laser cutting stands out because it can cut through a wide variety of materials. These include metals, polymers, wood, cloth, glass, and many more. Manufacturing, automotive, aerospace, and crafts are just a few of the many industries that make use of this technology due to its adaptability. Laser cutting is ideal for making complex parts, prototypes, signs, architectural models, and one-of-a-kind products due to the high level of accuracy and precise detail it can achieve.
Also, several kinds of lasers, like carbon dioxide (CO2) and fibre (FL) lasers, have been integrated into laser cutting technology; these have their own unique benefits in terms of cutting efficiency, speed, and material compatibility.
Computer control allows for speedy production and fine customisation. As a low-cost, high-precision technique for producing complex forms and designs with outstanding accuracy and reproducibility, laser cutting has transformed production and design procedures.
Table of Contents
Using a Laser for Cutting
To make a two-dimensional contour out of a flat piece of material, a laser cutter uses a vertically-directed, extremely-small-diameter, high-energy light beam that moves in two directions along a machine bed. This laser beam follows a predetermined pattern of computer-generated instructions known as G-code as it melts or burns through the material. The molten material is occasionally expelled from the bottom of the material being cut using a high-pressure gas stream.
The purpose of this procedure is to ensure that the debris does not collect in the incision region and harden once the beam has passed through. On the other hand, sometimes the material is only vaporised by the laser beam. While each technology uses a somewhat different approach to produce its laser beam, in theory they all boil down to the following:
Generation of G-code File
It is necessary to generate the G-code for the cutting task before any cutting can be carried out. G-code is a language that machines can understand and follow to direct the movement of the laser cutting head. For basic shapes, the operator can manually generate the instructions. G-code can be automatically generated from a provided CAD file using CAM software, which is especially useful for more complicated shapes. The next step is to transfer this G-code to the machine using a USB drive or Wi-Fi.
Laser Beam Generation
The resonator is responsible for producing the laser beam. The medium used to produce the laser varies across various laser systems. Regardless, the various laser technologies share the same physics behind beam creation.
An electron can jump to a higher energy level by soaking up the photon's energy. To bring an electron to a particular energy level, a precise quantity of photon energy is needed. Stimulated absorption is the name for this procedure.
The electron will quickly fall to a lower orbital as it decays. Deterioration occurs when the quantum vacuum returns to a lower energy state as a result of minute perturbations. It will release a photon when it decays. The term for this phenomenon is spontaneous emission.
Because the produced photons will be disorganised and scatter in all directions, a laser beam cannot be generated via spontaneous photon emission. Additionally, they will fall to the ground condition far too soon. By employing materials in a metastable condition, lasers are able to circumvent this problem. In contrast to the milliseconds or nanoseconds required for spontaneous emission, this procedure prolongs the amount of time an electron can stay in a semi-excited state.
The interaction between a photon and an excited, metastable electron can induce the electron to reenter a lower energy orbital. This causes the electron to emit a photon that is identical in frequency, phase, and polarisation as the photon that first disturbed it. A laser beam is generated through this technique, which is known as stimulated emission. As soon as it begins, a series of photons are discharged and make their way down the tube.
Laser Amplifier
The photons will scatter and go in all different directions when spontaneous emission first starts. But some of them will be in the opposite direction of the laser medium's two mirrors. The two light waves, which are propagating in opposite directions in the medium, combine to form a standing wave that includes both constructive and destructive interference. Resonance is the term used to describe the phenomenon of these standing waves.
The semi-reflective mirror lets some light through as the light intensity rises, creating a coherent beam of laser energy. The stimulated emission of photons is sustained because the leftover light reflects in the laser medium. The wavelengths of lasers are determined by the technology used to create them.
Directing and Concentrating the Beams
The beam is redirected as it leaves the amplification chamber of a fibre laser or a CO2 or Nd:YAG laser through a set of mirrors, depending on the kind of laser. Using a lens to concentrate the laser's beam into a very small diameter, a concentrated point of high energy is created and then directed downward into the sheet material.
Keep in mind that the laser's cutting power is concentrated in one spot, and not throughout the beam. Because the laser's strength decreases both above and below the focus point, the maximum thickness that a laser cutter can cut is determined by this intensity differential.
Fabrication
The substance will start to melt or vaporise as soon as the beam is focussed. The laser will vaporise or burn through wood and other non-melting materials. Metals can be melted using a laser beam, and then expelled from the incision using a high-pressure gas jet. The gas can be oxygen, which speeds up the cutting of steel, or inert gases like nitrogen or argon.
What Kinds of Sheet Metal Laser Cutting Are There?
These days, fibre and CO2 lasers are the norm for industrial sheet metal laser cutting.
CO2 Laser
A gas mixture primarily composed of carbon dioxide (CO2), helium, and nitrogen is used to generate the CO2 laser, also known as a carbon dioxide laser. One way to power such a laser is with an electric discharge.
Usually, the wavelength that CO2 lasers emit is 10.6 μm. The ones used to process materials can produce beams with a power output of several kilowatts. While CO2 lasers have a wall-plug efficiency of around 10%, it's lower than that of many diode-pumped lasers but higher than that of most lamp-pumped solid-state lasers (e.g., ND:YAG lasers).
At the same power level, a CO2 laser can cut through materials that are thicker than 5mm more quickly than a fibre laser. When cutting thicker materials, it also creates a smoother surface finish. The use of carbon dioxide (CO2) lasers for cutting sheet metals was the original method. A three-axis system, including X-Y and Z-axis height control, is standard for CO2 laser cutting machines.
Nonetheless, the X-Y movement can be accomplished in a variety of ways, including by adjusting the workpiece or the laser head, or even by combining the two. The 'flying optics' system is the most common, and it involves keeping the workpiece still while moving mirrors along the X and Y axes. An advantage of this method is that the mass being moved by the motors is always known and fixed. Although it is easier to anticipate and manage, this is frequently substantially heavier than the workpiece.
Since the workpiece remains in its original position, the sheet weight is effectively unlimited. A laser beam is never perfectly parallel; in fact, it actually diverges slightly as it leaves the laser, which is an issue with flying optics due to beam size variation. As a result, the cutting performance might vary across the table depending on the raw beam size if the divergence is not controlled. An adaptive mirror control system or a re-collimating optic can mitigate this effect.
An alternate method involves a 'fixed optic' setup, in which the component being worked on is moved along the X and Y axes while the laser head stays put. Visually, this is perfect, but mechanically, it's a nightmare, particularly for thicker sheets. As the sheet weighs more, accurately placing the material at high speed becomes more of a challenge; however, a fixed optic device can be a viable option for relatively light sheet weights.
The third choice is a "hybrid" system, which allows for the movement of both the material and the laser head along two separate axes. While this is generally an upgrade over fixed optics, it does have issues with thicker sheets.
Fibre Lasers
A type of laser known as a "fibre laser" belongs to the "solid-state laser" family. The beam is produced by a solid medium in solid-state lasers. Lasers that use fibres, discs, or Nd:YAG are all considered to be of the same type.
A string of laser diodes can produce a fibre laser beam. Following its transmission through an optical fibre, the laser beam is amplified, much like a traditional laser cavity in carbon dioxide lasers. After the amplified beam leaves the optical fibre, it is directed onto the material to be cut by means of a lens or concave. Several benefits are associated with fibre laser sources:
A fibre laser source generates light without the use of mirrors or moving components, unlike a traditional CO2 resonator. In terms of lowering operational expenses and maintenance needs, this is a huge benefit.
In comparison to CO2 lasers of equivalent power, fibre lasers are usually 2-3 times more energy efficient.
A fibre laser outperforms a CO2 laser of identical power when it comes to cutting thin sheets. The cutting front has superior wavelength absorption for fibre lasers, which is responsible for this.
Fibre lasers can cut through reflective materials without getting damaged by back reflections. Because of this, metals like aluminium, copper, and brass can be cut easily.
Direct Diode Lasers
New developments in solid-state laser technology include direct diode lasers. Beam combining techniques are employed in this technology to superimpose multiple laser beams produced by laser-emitting diodes with varying wavelengths. Due to the absence of a brightness-enhancing stage, direct diode lasers have lower optical losses and better wall-plug efficiency compared to fibre lasers.
Nonetheless, fibre lasers produce higher-quality beams than direct diode lasers at the moment, and the reason behind this is the same. Sheet metal cutting has been made possible with commercially available, multi-kilowatt direct diode lasers.
5 Advantages Of Laser Cutting In Manufacturing
Cutting is a typical operation in the manufacturing sector. Cutting is typically necessary when working with materials or preassembled components. Cutting shears are still used by some manufacturers, but more modern techniques like laser cutting are replacing them. In keeping with its moniker, laser cutting involves penetrating materials and workpieces with an intense beam of light. The following are just a few of the many benefits it provides to manufacturing companies.
Accommodates All Resources
Laser cutting is compatible with almost any material. It effortlessly slices through metals that are typically considered to be strong and tough, like titanium, stainless steel, aluminium, and copper. One basic principle of laser cutting is the localised melting of material by means of a focused laser beam. Anything that comes into contact with the laser beam will be melted as it gets hotter. It doesn't matter how strong or hard a material is; the high temperature of the laser beam will cut through it.
Delicate Corners
Smooth edges are another benefit of laser cutting in production. Naturally, sharp edges are frequently the result of using traditional cutting shears. A pair of shears will produce edges that are sharp and jagged when you cut through material. This is not an issue with laser cutting. It will melt the material and then smooth its edges because it employs heat.
Accuracy
Because of its precision, laser cutting is ideal for certain tasks. It allows manufacturers to precisely cut through materials to obtain desired proportions. When it comes to dimensions, some laser cutting equipment are as precise as 0.0005 inches.
Compared to the dimensional accuracy of more conventional cutting tools, such shears, that is light years ahead of the competition. Laser cutting is favoured by manufacturing businesses due to its exceptional precision.
Laser cutting machines come in several varieties. They use neodymium (Nd) lasers and carbon dioxide (CO2) lasers, respectively. Regardless, each of them is capable of slicing through various materials with pinpoint accuracy.
Robotic
It is possible to automate laser cutting. You can use it with CNC systems, or computer numerical control. Computer numerical control (CNC) laser cutting machines are available. The cutting process can be programmed using a computer. After that, the laser cutting machine will use those commands to make precise cuts in the material.
Cuts Down on Energy Use
Although it still uses energy, laser cutting is thought to be more efficient than a lot of other cutting techniques. It simplifies and speeds up cutting procedures for manufacturing organisations. Compared to other cutting techniques, laser cutting usually uses less energy due to its high operating speeds.
Conclusion
Laser cutting is a versatile and accurate method used in various industries, including manufacturing, automotive, aerospace, and crafts. It uses a concentrated beam of light energy to create precise cuts or engravings, allowing for the creation of complex forms or designs from various materials. Laser cutting is ideal for making complex parts, prototypes, signs, architectural models, and unique products due to its high level of accuracy and detail.
Various types of lasers, such as carbon dioxide (CO2) and fiber (FL) lasers, have been integrated into laser cutting technology, offering unique benefits in terms of cutting efficiency, speed, and material compatibility. Computer control allows for speedy production and fine customization.
Laser cutting uses a vertically-directed, extremely-small-diameter, high-energy light beam that moves in two directions along a machine bed. The laser beam follows a predetermined pattern of computer-generated instructions known as G-code, which can be generated manually or automatically from a provided CAD file using CAM software.
Laser beam generation involves the resonator producing the laser beam, which is generated through stimulated absorption and spontaneous emission. This method prolongs the amount of time an electron can stay in a semi-excited state, allowing for more accurate and precise cutting.
Lasers are used in industrial sheet metal laser cutting to create a coherent beam of energy. The beam is directed through a set of mirrors, focusing the laser's energy into a small diameter. The maximum thickness a laser cutter can cut depends on the intensity differential. The laser then melts or vaporizes the substance, melting or burning through non-melting materials.
There are two main types of sheet metal laser cutting: fibre and CO2 lasers. The CO2 laser, a gas mixture of carbon dioxide (CO2), helium, and nitrogen, emits a wavelength of 10.6 μm and can cut through materials thicker than 5mm more quickly than a fibre laser. It has a wall-plug efficiency of around 10% and can cut through materials thicker than 5mm more quickly.
The X-Y movement can be achieved through various methods, including adjusting the workpiece or the laser head, or combining the two. The 'flying optics' system is the most common, involving keeping the workpiece still while moving mirrors along the X and Y axes. However, this method is often heavier than the workpiece and can cause beam size variation.
An alternate method is the 'fixed optic' setup, which moves the component along the X and Y axes while the laser head remains put. This is ideal for relatively light sheet weights but can be challenging for thicker sheets.
Fibre lasers are a type of solid-state laser that produce a beam using a string of laser diodes. They are energy-efficient and can cut through reflective materials like aluminum, copper, and brass without damage. Direct diode lasers are new developments in solid-state laser technology that use beam combining techniques to produce multiple laser beams with varying wavelengths. They have lower optical losses and better wall-plug efficiency compared to fibre lasers.
Laser cutting is a popular technique in manufacturing, as it can accommodate almost any material and achieve precise cuts. It is compatible with strong and tough materials like titanium, stainless steel, aluminum, and copper. Laser cutting machines come in various types, including neodymium (Nd) and carbon dioxide (CO2) lasers, and can be automated using CNC systems or computer numerical control (CNC) laser cutting machines.
Laser cutting is also considered more efficient than other cutting techniques, as it simplifies and speeds up cutting procedures for manufacturing organizations. Its high operating speeds make it a more efficient choice for manufacturing operations. Overall, laser cutting offers numerous advantages in the manufacturing sector, including improved efficiency, reduced energy use, and improved productivity.
Content Summary:
- Many different types of companies make use of laser cutting because of how accurate and flexible it is for cutting and engraving materials.
- Laser cutting stands out because it can cut through a wide variety of materials.
- Laser cutting is ideal for making complex parts, prototypes, signs, architectural models, and one-of-a-kind products due to the high level of accuracy and precise detail it can achieve.
- As a low-cost, high-precision technique for producing complex forms and designs with outstanding accuracy and reproducibility, laser cutting has transformed production and design procedures.
- To make a two-dimensional contour out of a flat piece of material, a laser cutter uses a vertically-directed, extremely-small-diameter, high-energy light beam that moves in two directions along a machine bed.
- This laser beam follows a predetermined pattern of computer-generated instructions known as G-code as it melts or burns through the material.
- While each technology uses a somewhat different approach to produce its laser beam, in theory they all boil down to the following: Generation of G-code File It is necessary to generate the G-code for the cutting task before any cutting can be carried out.
- G-code is a language that machines can understand and follow to direct the movement of the laser cutting head.
- The resonator is responsible for producing the laser beam.
- Because the produced photons will be disorganised and scatter in all directions, a laser beam cannot be generated via spontaneous photon emission.
- By employing materials in a metastable condition, lasers are able to circumvent this problem.
- The interaction between a photon and an excited, metastable electron can induce the electron to reenter a lower energy orbital.
- A laser beam is generated through this technique, which is known as stimulated emission.
- Resonance is the term used to describe the phenomenon of these standing waves.
- The semi-reflective mirror lets some light through as the light intensity rises, creating a coherent beam of laser energy.
- The beam is redirected as it leaves the amplification chamber of a fibre laser or a CO2 or Nd:YAG laser through a set of mirrors, depending on the kind of laser.
- Using a lens to concentrate the laser's beam into a very small diameter, a concentrated point of high energy is created and then directed downward into the sheet material.
- Keep in mind that the laser's cutting power is concentrated in one spot, and not throughout the beam.
- These days, fibre and CO2 lasers are the norm for industrial sheet metal laser cutting.
- One way to power such a laser is with an electric discharge.
- The use of carbon dioxide (CO2) lasers for cutting sheet metals was the original method.
- A three-axis system, including X-Y and Z-axis height control, is standard for CO2 laser cutting machines.
- A type of laser known as a "fibre laser" belongs to the "solid-state laser" family.
- The beam is produced by a solid medium in solid-state lasers.
- A string of laser diodes can produce a fibre laser beam.
- A fibre laser outperforms a CO2 laser of identical power when it comes to cutting thin sheets.
- New developments in solid-state laser technology include direct diode lasers.
- Nonetheless, fibre lasers produce higher-quality beams than direct diode lasers at the moment, and the reason behind this is the same.
- Cutting is a typical operation in the manufacturing sector.
- One basic principle of laser cutting is the localised melting of material by means of a focused laser beam.
- Smooth edges are another benefit of laser cutting in production.
- Naturally, sharp edges are frequently the result of using traditional cutting shears.
- A pair of shears will produce edges that are sharp and jagged when you cut through material.
- Because of its precision, laser cutting is ideal for certain tasks.
- When it comes to dimensions, some laser cutting equipment are as precise as 0.0005 inches.
- Robotic It is possible to automate laser cutting.
- Computer numerical control (CNC) laser cutting machines are available.
- The cutting process can be programmed using a computer.
- After that, the laser cutting machine will use those commands to make precise cuts in the material.
- Use Although it still uses energy, laser cutting is thought to be more efficient than a lot of other cutting techniques.
- Compared to other cutting techniques, laser cutting usually uses less energy due to its high operating speeds.
Frequently Asked Questions
The most common types of lasers used in cutting applications include CO2 (carbon dioxide) lasers and fiber lasers. CO2 lasers are well-suited for cutting non-metallic materials like wood, acrylic, and plastics, while fiber lasers are highly effective for cutting metals such as stainless steel, aluminum, and brass.
Yes, laser cutting is often used in mass production due to its speed, accuracy, and repeatability. It allows for efficient cutting of multiple identical parts or components, making it a preferred method in industries such as automotive, electronics, signage, and more.
Yes, besides cutting, lasers can be used for engraving, etching, and marking materials. Laser engraving creates shallow indentations or markings on surfaces, while laser etching modifies the material's surface properties. Laser marking involves adding serial numbers, logos, or barcodes for identification purposes.
Several factors influence the quality of laser-cut parts, including laser power, cutting speed, focus, material properties, and the design of the cutting path. Optimal settings and precise calibration of the laser machine are crucial for achieving high-quality cuts with clean edges and minimal distortion.
Yes, safety is paramount when working with laser cutting machines. Operators should use appropriate protective gear, ensure proper ventilation to remove fumes or gases generated during cutting, and follow safety protocols to prevent accidents. Laser systems should be installed and maintained according to manufacturer guidelines to minimize risks.