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laser microjet

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1. การแนะนำ

Laser MicroJet (LMJ) is a groundbreaking hybrid technology that combines the precision of a laser beam with the cooling and cleaning effects of a water jet.

Guides a laser beam within a hair-thin water jet enabling a long working length.

This innovative approach addresses many challenges in traditional laser cutting processes, particularly heat-affected zones (ฮาซ) and debris buildup.

The technology has found broad applications in industries requiring high-precision, clean cutting, and offers this advanced solution to industries that demand extreme precision.

LMJ features easy set-up, high precision, small kerf, and good edge quality. Compared with conventional dry laser processing, it can process thicker material with much less HAZ.

Wire-EDM (electrical discharge machining) ในทางกลับกัน, shows characteristics similar to that of LMJ but has a slower set-up and a lower process speed.

อย่างไรก็ตาม, wire-EDM could be more economical depending on the product geometry and product quantity, as will be discussed later.

LMJ principlt
LMJ principle

2. How Does Laser MicroJet Work?

LMJ technology utilizes a laser beam encapsulated in a thin, high-pressure water jet. The water jet acts as an optical guide for the laser beam, keeping it focused and ensuring that the cutting process remains stable over longer distances.

Unlike traditional laser cutting, where heat buildup can distort materials, the water jet in LMJ cools the workpiece during cutting.

This cooling effect significantly reduces the risk of thermal damage and allows for cuts to be made without the typical heat-affected zone. The water jet also removes debris from the cutting path, ensuring a cleaner and smoother cut.

Key components of an LMJ system include a laser source, optical head, water management system, and a multi-axis motion control system. These components enable high-precision machining, such as cutting, การขุดเจาะ, and grooving, on a variety of materials.

laser microjet
laser microjet

3. Advantages of LMJ

  • No Heat-Affected Zones (ฮาซ): The water jet provides continuous cooling, preventing the material from overheating and reducing the chances of thermal distortion.
  • ความแม่นยำสูง: LMJ offers extremely accurate cutting, ideal for high-tolerance applications in industries like aerospace, อุปกรณ์ทางการแพทย์, และอุปกรณ์อิเล็กทรอนิกส์.
  • Cleaner Cuts: The water jet flushes debris away during the process, leaving a clean cut and reducing the need for secondary finishing steps.
  • การสึกหรอของเครื่องมือน้อยที่สุด: Since the water jet prevents the laser from direct contact with the material, tool wear is significantly reduced, enhancing the longevity of the cutting equipment.
  • ความเก่งกาจ: LMJ is effective across a wide range of materials, รวมทั้งโลหะด้วย, เซรามิกส์, และคอมโพสิต.

4. Characteristics of LMJ

• Cutting small but complex functional parts from thin sheet metal (from 0.02 ขึ้นไป 2-3 มม) with feature sizes down to 50 µm and precision within a few µm.

• Precision drilling of small holes in thin sheet metal up to a certain aspect ratio.

• Creating flexible mechanisms, such as springs, in thin sheet metal.

• Precision cutting of other materials aforementioned with a thickness up to a cm, particularly for insulating materials that cannot be processed with EDM.

• Integration with die-sinking EDM and PECM technology for cutting precision contours, ideally suited for prototypes and small and medium-sized batch production; and with wire-EDM for the precision manufacturing of small start holes.

5. Metals that Can Be Machined with LMJ

Laser MicroJet technology is versatile and can be used to machine a variety of materials, รวมทั้ง:

  • เหล็ก: Ideal for both hard and soft grades, including stainless steel and high-strength alloys.
  • อลูมิเนียม: The cooling effect of the water jet makes it possible to machine aluminum with minimal thermal distortion.
  • ไทเทเนียม: Known for its strength and heat resistance, titanium can be cut cleanly using LMJ without compromising its integrity.
  • ทองแดง: LMJ’s precision makes it suitable for cutting conductive materials like copper, often used in electronics.
  • Ceramics: Advanced ceramics, which are often brittle, can be machined cleanly with LMJ without cracking or chipping.

6. Applications of Laser MicroJet

LMJ technology finds use in several industries that require precision cutting and machining. การใช้งานที่สำคัญได้แก่:

  • การบินและอวกาศ: High-precision drilling and cutting of turbine blades and other components where material integrity and edge quality are paramount.
  • Semiconductors and Electronics: LMJ enables the precise cutting of semiconductors and circuit boards without damaging sensitive components. Cutting of micro-components, semiconductors, and wafers used in electronics manufacturing.
  • อุปกรณ์การแพทย์: The technology is widely used for the precision cutting of surgical instruments and implants, where accuracy and biocompatibility are paramount.
  • ยานยนต์: For high-performance vehicles, LMJ is used to machine lightweight, strong components that require minimal distortion during fabrication.

7. Laser MicroJet vs. ไวร์อีดีเอ็ม: A Comparison

Heat-Affected Zone (ฮาซ)

  • LMJ: One of the standout benefits of Laser MicroJet is the absence of a heat-affected zone due to the water jet’s cooling effect. This makes LMJ suitable for materials where thermal distortion could compromise the component’s performance or quality.
  • ไวร์อีดีเอ็ม: Wire EDM also generates minimal heat, but since it uses an electrical discharge process, there is still some risk of heat buildup around the cutting area. อย่างไรก็ตาม, this risk is minimal compared to traditional dry laser cutting methods.

Precision and Tolerances

  • LMJ: Provides extremely high precision with the ability to hold tight tolerances, making it a preferred option for components requiring superior accuracy.
  • ไวร์อีดีเอ็ม: Wire EDM is renowned for its precision, often providing tolerances as low as ±0.0001 inches. It excels in complex, intricate shapes, particularly for conductive materials.

Material Range

  • LMJ: LMJ can cut a wide variety of materials, รวมทั้งโลหะด้วย, เซรามิกส์, and even brittle materials like glass or silicon wafers. Its versatility makes it suitable for industries like aerospace and electronics.
  • ไวร์อีดีเอ็ม: While Wire EDM is highly effective on conductive materials such as steel, อลูมิเนียม, และไทเทเนียม, it is less effective on non-conductive materials, limiting its applications in areas where non-metals or composites are predominant.

Speed and Efficiency

  • LMJ: The process can be faster than Wire EDM, especially for thicker materials, due to the water-jet-guided laser cutting through materials more quickly and with greater efficiency.
  • ไวร์อีดีเอ็ม: Wire EDM can be slow, especially when cutting thicker materials. อย่างไรก็ตาม, it remains unmatched for its ability to handle highly complex shapes and geometries that other cutting technologies might struggle with.

การพิจารณาต้นทุน

  • LMJ: While LMJ machines tend to be more expensive upfront, they offer cost savings over time in terms of faster cycle times, reduced tool wear, and minimal post-processing due to the high-quality finish.
  • ไวร์อีดีเอ็ม: EDM machines are typically less expensive upfront, but operational costs may increase over time due to slower cutting speeds and tool wear.

พื้นผิวเสร็จสิ้น

  • LMJ: LMJ is known for providing a high-quality, mirror-like surface finish due to the water jet’s cleaning action during cutting.
  • ไวร์อีดีเอ็ม: Wire EDM can also deliver excellent surface finishes, but it may require additional finishing steps, depending on the material and the desired quality.

การใช้งาน

  • LMJ: Ideal for industries that need high precision, clean cuts, and minimal post-processing, เช่นการบินและอวกาศ, อุปกรณ์ทางการแพทย์, and semiconductors.
  • ไวร์อีดีเอ็ม: Typically used for intricate shapes in conductive materials, such as mold-making, ตาย, and high-precision mechanical components.

7. บทสรุป

Laser MicroJet offers unparalleled precision, ประสิทธิภาพ, and versatility in material machining. Whether you’re working with metals, เซรามิกส์, or composites, LMJ provides cleaner, faster, and more accurate cuts than traditional methods.

Compared to Wire EDM, LMJ stands out in terms of material versatility, ความเร็ว, and reduced heat effects, making it an excellent choice for industries requiring tight tolerances and high-quality finishes.

8. DEZE’s CNC Laser MicroJet Services

กินนี่, we offer cutting-edge Laser MicroJet services that deliver superior results for your most demanding projects. Our expert team ensures precision, คุณภาพ, and fast turnaround times across a wide range of industries.

Whether you need high-precision components or intricate machining, DEZE has the tools and expertise to meet your requirements.

คำถามที่พบบ่อย

ถาม: Can LMJ cut non-metal materials?

ก: ใช่, LMJ is capable of cutting non-metals such as ceramics and composites with high precision and minimal damage.

ถาม: What industries benefit most from LMJ?

ก: LMJ is widely used in aerospace, อุปกรณ์ทางการแพทย์, อิเล็กทรอนิกส์, and automotive industries where precision and clean cuts are critical.

ถาม: What is the advantage of using LMJ over traditional laser cutting?

ก: LMJ eliminates heat-affected zones and provides cleaner, more precise cuts with minimal post-processing.

ถาม: How does LMJ compare to Wire EDM?

ก: LMJ is faster, offers more versatility across materials, and prevents heat damage, while Wire EDM excels in precision and complex geometries for conductive materials.

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