What is Laser Cutting？

Laser cutting technology has transformed the manufacturing sector by providing precision and versatility that traditional cutting methods cannot match.

Originating in the late 1960s, laser cutting has undergone significant advancements, evolving from basic systems into highly sophisticated, computer-controlled machines.

Сьогодні, it plays a vital role in various industries, включаючи аерокосмічний, автомобільний, та електроніка, enabling the production of complex components with exceptional accuracy and efficiency.

This blog post delves into the intricacies of laser cutting, exploring its process, типи, переваги, заявки, and costs.

1. Що таке лазерне різання?

У своїй основі, laser cutting involves directing a high-powered laser beam onto a material’s surface to either melt, спалювати, or vaporize it, creating a cut.

The laser beam is generated by a laser source, which produces a concentrated light beam that can be focused to a very small point.

This concentrated energy allows for highly detailed and intricate cuts that are difficult to achieve with traditional cutting methods.

2. How Laser Cutting Works

Laser cutting is a precise and efficient method of cutting materials using a high-powered laser beam.

The process involves several key steps and components that work together to achieve accurate and clean cuts. Here’s a detailed breakdown of how laser cutting works:

Laser Generation

• Excitation of the Lasing Medium: The first step in the laser cutting process is the generation of the laser beam.
  This is achieved by exciting a lasing medium, which can be a gas (like CO2), a solid (like Nd: YAG), or a fiber (like in fiber lasers).

• • CO2 лазери: A mixture of gases (typically CO2, азот, and helium) is electrically stimulated to produce a laser beam.
  • Волоконні лазери: A diode pump source excites a rare-earth-doped fiber optic cable to generate the laser beam.
  • Nd: YAG лазери: A flash lamp or diode pump excites a neodymium-doped yttrium aluminum garnet crystal to produce the laser beam.

Beam Focusing

• Optical Components: The generated laser beam is directed and focused using a series of mirrors and lenses.
• Focusing Lens: The final lens focuses the laser beam to a small spot on the material, зазвичай між 0.001 і 0.005 inches in diameter.
  This concentration of energy results in a very high power density.
• Beam Delivery System: The focused beam is delivered to the material via a cutting head, which can move in multiple axes to follow the desired cutting path.

Material Interaction

• Heat Generation: The focused laser beam generates intense heat at the point of contact with the material.
  The temperature can reach thousands of degrees Celsius, causing the material to melt, спалювати, або випаровуватися.
• Cutting Mechanism:

• • плавлення: For materials with high thermal conductivity (like metals), the heat causes the material to melt.
  • Burning: For combustible materials (like wood or paper), the heat causes the material to burn.
  • Vaporization: For materials with a low boiling point (як пластмаса), the heat causes the material to vaporize.

Assist Gases

• Role of Assist Gases: Assist gases are often used to enhance the cutting process and improve cut quality.

• • Кисень: For cutting metals, oxygen is used to support the exothermic reaction, which helps to cut through the material more efficiently.
  • Азот: For cutting metals, nitrogen is used to shield the cut edge from oxidation, resulting in a cleaner and smoother cut.
  • Air: For cutting non-metals, air can be used to blow away the molten or burned material, забезпечення чистого зрізу.

Cutting Path Control

• Computer Control: The cutting path is controlled by a computer-aided design (Кот) and computer-aided manufacturing (Кулачок) система.
  The CAD software designs the shape to be cut, and the CAM software translates this design into machine code that controls the movement of the cutting head.
• Motion System: The cutting head is mounted on a motion system that can move in multiple axes (X, Ю, and sometimes Z).
  This allows the laser to follow the precise path defined by the CAD/CAM software.

Cooling and Safety

• Cooling System: To prevent overheating and ensure consistent performance, the laser cutting machine is equipped with a cooling system.
  This can be water-cooled or air-cooled, depending on the type and size of the laser.
• Safety Measures: Laser cutting involves high-intensity light and potentially hazardous materials. Safety measures include:

• • Enclosed Work Area: The cutting area is typically enclosed to prevent laser radiation from escaping.
  • Protective Eyewear: Operators must wear appropriate protective eyewear to shield their eyes from the laser beam.
  • Ventilation System: A ventilation system is used to remove fumes and particulates generated during the cutting process.

3. Main Types of Laser Cutters

Laser-cutting technology offers a variety of options, each tailored to specific materials and applications. The main types of laser cutters are:

CO2 Laser Cutters

CO2 lasers operate by emitting a high-power laser beam through a series of mirrors and lenses, focusing it to a pinpoint accuracy.
The laser beam interacts with the material’s surface, heating it to the point of vaporization or melting, thereby creating the desired cut.

Характеристики:

• Wavelength: 10.6 мікрометри
• Power Output: Typically ranges from 200 до 10,000 watts
• Матеріальна придатність: Excellent for cutting non-metallic materials and thinner metals
• Ефективність: Lower electrical efficiency (навколо 10%)

Заявки:

• Non-metallic materials: Деревина, акрил, cardboard, папір, тканина, and leather
• Thinner Metals: Вуглецева сталь, нержавіюча сталь, and aluminum up to 10-20 мм товщиною

Переваги:

• Висока точність: Capable of achieving very fine cuts and detailed work
• Універсальність: Suitable for a wide range of materials
• Економічний: Lower initial cost compared to other types

Недоліки:

• Limited to Thinner Metals: Not ideal for cutting thicker metals
• Технічне обслуговування: Requires regular maintenance of the gas mixture and optical components

Fiber Laser Cutters

Fiber laser cutting utilizes a high-power laser generated through fiber optics, focusing a concentrated beam onto the material’s surface.
This method excels in the precise cutting of thin to medium-thickness materials such as stainless steel, алюміній, and alloys.

Характеристики:

• Wavelength: 1.064 мікрометри
• Power Output: Діапазон від 20 до 15,000 watts
• Матеріальна придатність: Excellent for cutting metals, especially reflective ones
• Ефективність: Higher electrical efficiency (до 30%)

Заявки:

• Метали: Нержавіюча сталь, вуглецева сталь, алюміній, and other reflective metals
• Товщина: Capable of cutting metals up to 30 мм товщиною

Переваги:

• High Efficiency: Lower power consumption and higher cutting speed
• Низьке обслуговування: Fewer moving parts and less frequent maintenance
• Reflective Material Compatibility: Can cut highly reflective metals without damaging the laser

Недоліки:

• Більш висока початкова вартість: More expensive than CO2 laser cutters
• Limited to Metals: Not suitable for non-metallic materials

Nd:YAG (Neodymium-Doped Yttrium Aluminum Garnet) Laser Cutters

(Neodymium-doped Yttrium Aluminum Garnet) laser cutting utilizes a crystal rod as the lasing medium, producing a high-energy laser beam.
This method is particularly suited for thicker materials and applications requiring robust cutting capabilities.

Характеристики:

• Wavelength: 1.064 мікрометри
• Power Output: Діапазон від 100 до 4,000 watts
• Матеріальна придатність: Suitable for a variety of materials, включаючи метали, кераміка, and plastics
• Ефективність: Moderate electrical efficiency (навколо 3%)

Заявки:

• Метали: Нержавіюча сталь, вуглецева сталь, та інші метали
• Ceramics and Plastics: High-precision cutting and drilling
• Товщина: Capable of cutting thick materials up to 50 мм

Переваги:

• Висока точність: Excellent for intricate and detailed work
• Універсальність: Suitable for a wide range of materials
• Pulsed Operation: Can operate in both continuous and pulsed modes, making it versatile for different applications

Недоліки:

• Більш висока початкова вартість: More expensive than CO2 laser cutters
• Технічне обслуговування: Requires regular maintenance of the lamp and optical components
• Size and Complexity: Larger and more complex systems compared to fiber and CO2 lasers

Comparison of Laser Types

	CO2 laser	Crystal Lasers (Nd: YAG or Nd: YVO)	Fiber Laser
State	Gas based	Solid state	Solid state
Material type	Деревина, акрил, скло, папір, текстиль, пластмаса, foils and films, leather, stone	Метали, метали з покриттям, пластмаса, кераміка	Метали, метали з покриттям, пластмаса
Pump source	Gas discharge	Lamp, diode laser	Diode laser
Wavelength (мкм)	10.6	1.06	1.07
Ефективність (%)	10	2 – lamp, 6 – diode	<30
Spot Diameter (мм)	0.15	0.3	0.15
MW/cm2 power density	84.9	8.5	113.2

4. What are the Main Settings and Parameters of Laser Cutting?

Laser cutting relies on specific parameters and settings that control the laser’s intensity, focus, швидкість, and other critical factors essential for achieving optimal results.
Each parameter significantly influences cutting quality and efficiency across various materials.

Лазерна сила

Laser power indicates the intensity of the laser beam used for cutting, and it is a fundamental parameter that directly affects cutting ability and speed.
Typically measured in watts (Ш), laser power ranges from 1,000 до 10,000 watts (1-10 kw), depending on the material and thickness being processed.

Laser Beam Mode (TEM Mode)

The laser beam mode, also known as Transverse Electromagnetic Mode (TEM Mode), defines the shape and quality of the laser beam profile.

The TEM00 mode, characterized by a Gaussian beam profile, is commonly used for precise cutting applications.

Material Thickness

Material thickness refers to the dimension of the material being cut, varying significantly based on the application and material type.

Laser cutting can handle materials ranging from thin sheets (0.1 мм) to thicker plates (до 25 мм), making it versatile for industries such as automotive, аерокосмічний, та електроніка.

Cutting Speed

Cutting speed indicates how quickly the laser moves across the material’s surface during the cutting process.

Measured in meters per minute (m/min), it typically ranges from 1 m/min to 20 m/min.

Optimizing cutting speed strikes a balance between efficiency and quality, ensuring precise cuts without compromising material integrity.

Assist Gas Pressure

Assist gas pressure is crucial in laser cutting as it blows away molten material from the cut, ensuring clean edges.

The pressure of the assist gas, whether oxygen or nitrogen, is usually maintained between 5 bar and 20 бар, depending on the material and cutting requirements.

Focus Position

Focus position denotes the distance between the laser lens and the material surface, determining where the laser beam achieves maximum intensity for efficient cutting.

Adjusting the focus position (зазвичай між 0.5 мм і 5 мм) is vital for maintaining cutting precision across different material thicknesses.

Pulse Frequency

Pulse frequency defines how often the laser emits pulses during the cutting process, varying from single pulses to frequencies in the kilohertz (kHz) діапазон.

Optimizing pulse frequency enhances cutting efficiency and heat distribution, leading to the desired cut quality and edge finish.

Beam Diameter/Spot Size

Beam diameter, or spot size, refers to the size of the laser beam at its focal point, typically maintained between 0.1 мм і 0.5 mm for high-precision cutting.

Controlling beam diameter ensures accurate material removal and minimizes heat-affected zones, which is crucial for intricate cutting tasks.

Cutting Gas Type

The type of cutting gas used—such as oxygen, азот, or a mixture—significantly impacts the cutting process and results.

Different gases react uniquely with materials, influencing cut quality, швидкість, and edge finish. Choosing the right cutting gas type is essential for achieving the desired outcomes.

Nozzle Diameter

Nozzle diameter refers to the diameter of the nozzle through which the assist gas flows onto the material surface.

It should match the beam diameter for effective material removal and clean cuts.

Типово, nozzle diameter ranges from 1 мм до 3 мм, depending on the application and material thickness.

5. Переваги лазерного різання

Laser-cutting technology offers numerous benefits that make it a preferred choice in various manufacturing applications. Here are the key advantages:

Точність та точність

Laser cutting is renowned for its high precision and ability to achieve tight tolerances, Часто в межах ± 0,1 мм.

The focused laser beam allows for intricate designs and detailed cuts, making it ideal for applications that demand exact specifications.

This level of accuracy reduces the need for secondary operations, saving time and costs.

Efficiency and Speed

One of the standout features of laser cutting is its speed. Laser machines can operate continuously and cut at rapid speeds, significantly enhancing productivity.

Наприклад, a fiber laser can cut through metals at speeds exceeding 30 meters per minute, depending on material thickness.

This efficiency reduces overall production times, making it suitable for both small and large-scale manufacturing.

Гнучкість матеріалу

Laser cutting is versatile and capable of cutting a wide range of materials, включаючи метали (like steel, алюміній, і титан), пластмаса, деревина, скло, and even textiles.

This flexibility allows manufacturers to use laser cutting for various applications, from prototyping to final production across multiple industries.

Економічна ефективність

Despite the initial investment in laser cutting equipment, the long-term savings are substantial.

Laser cutting minimizes material waste due to its precise cutting capabilities, reducing overall material costs.

Додатково, the speed and efficiency of laser cutting lead to lower operational costs over time, making it a cost-effective solution for manufacturers.

Environmental Benefits

Laser cutting is more environmentally friendly compared to traditional cutting methods. It generates minimal waste and emissions, thanks to its precise cutting capabilities.

The technology often requires fewer resources for cleanup and secondary operations, further reducing its environmental footprint.

Більше, advancements in laser technology have led to more energy-efficient machines, внесок у практику сталого виробництва.

Minimal Tool Wear

Unlike mechanical cutting methods, laser cutting does not involve physical contact with the material, which results in minimal wear and tear on tools.

This lack of contact reduces maintenance costs and extends the lifespan of the cutting equipment, making it a reliable choice for manufacturers.

Універсальні програми

Laser cutting is suitable for a wide array of applications across various industries, включаючи автомобільну, аерокосмічний, електроніка, and custom fabrication.

Its ability to create intricate designs and precise cuts makes it invaluable for producing everything from complex components to decorative elements.

6. Disadvantages of Laser Cutting

While laser cutting offers numerous benefits, it also comes with certain drawbacks that manufacturers should consider. Here are the main disadvantages of laser cutting technology:

Початкова вартість

One of the most significant barriers to adopting laser cutting technology is the high initial investment required for equipment.

Industrial-grade laser cutting machines can be expensive, which may deter smaller businesses or startups from utilizing this technology.

Додатково, the cost of maintenance and repairs can add to the overall financial burden.

Технічне обслуговування

Laser-cutting machines require regular maintenance to ensure optimal performance and precision. This includes calibration, lens cleaning, and periodic inspections.

Failure to maintain the equipment properly can lead to decreased cutting quality, довший час виробництва, and increased operational costs.

For businesses with limited technical expertise, this can pose a challenge.

Material Limitations

Not all materials are suitable for laser cutting. Reflective metals, such as copper and brass, can cause issues by reflecting the laser beam, potentially damaging the equipment.

Додатково, certain materials may produce hazardous fumes or debris during cutting, requiring proper ventilation and safety measures.

Safety Concerns

Laser cutting presents safety risks, including potential eye injuries from the laser beam and fire hazards from the high temperatures generated during cutting.

Operators must adhere to strict safety protocols, wear protective gear, and ensure proper machine operation to mitigate these risks.

Implementing safety measures can increase operational complexity and costs.

Heat-Affected Zones (Хаз)

The high temperatures generated during laser cutting can create heat-affected zones (Хаз) around the cut edges.

These areas may experience changes in material properties, such as hardness or brittleness, which can affect the integrity of the finished product.

In applications requiring precise material characteristics, this can be a critical concern.

Limited Thickness Capability

While laser cutting excels at processing thin to moderately thick materials, it may struggle with extremely thick materials.

The cutting speed may decrease significantly as material thickness increases, leading to longer processing times and potential challenges in achieving clean cuts.

For thicker materials, other cutting methods, such as plasma cutting, may be more effective.

Dependence on Operator Skill

The efficiency and quality of laser cutting are heavily dependent on the skill level of the operator.

Proper setup, Вибір матеріалу, and machine calibration require a trained and experienced technician.

A lack of expertise can result in poor-quality cuts, increased waste, and production delays.

7. Applications of Laser Cutting

Laser cutting is utilized across a diverse range of industries:

Промислові програми

• Автомобільна промисловість: Precision cutting of components such as brackets and chassis parts.
• Аерокосмічна промисловість: Manufacturing critical structural elements that require high accuracy.
• Електроніка: Cutting circuit boards and components with minimal tolerances.

Споживчі товари

• Jewelry and Accessories: Creating intricate designs that require fine detail.
• Home Decor and Furniture: Custom pieces tailored to individual preferences.

Медичні програми

• Хірургічні інструменти: Precision cutting for tools and instruments used in surgical procedures.
• Implants and Prosthetics: Tailoring solutions to fit specific patient needs.

Art and Design

• Custom Art Pieces: Producing unique designs for sculptures and decorative items.
• Signage and Engraving: High-quality engraved signs and promotional displays.

8. Material Considerations in Laser Cutting

When selecting materials for laser cutting, it’s crucial to consider various factors such as material type, товщина, and properties.

These considerations can significantly impact the cutting process, quality, і ефективність. Here’s a detailed look at the material considerations for laser cutting:

Material Types

Метали:

• Нержавіюча сталь:

• • Властивості: Висока сила, Корозійна стійкість, and reflectivity.
  • Придатність: Best cut with fiber lasers due to their high reflectivity.
  • Заявки: Автомобільний, аерокосмічний, Медичні пристрої.

• Вуглецева сталь:

• • Властивості: High strength and durability.
  • Придатність: Can be cut with both CO2 and fiber lasers.
  • Заявки: Будівництво, виробництво, автомобільний.

• Алюміній:

• • Властивості: Легкий, Висока теплопровідність, and reflectivity.
  • Придатність: Best cut with fiber lasers due to its reflectivity.
  • Заявки: Аерокосмічний, електроніка, автомобільний.

• Мідь і Латунь:

• • Властивості: High thermal conductivity and reflectivity.
  • Придатність: Challenging to cut; requires specialized techniques and higher power lasers.
  • Заявки: Electrical components, ювелірні вироби, декоративні предмети.

Non-Metals:

• Акрилові:

• • Властивості: Transparent, easy to cut, and produces a smooth edge.
  • Придатність: Best cut with CO2 lasers.
  • Заявки: Вивіски, displays, декоративні предмети.

• Деревина:

• • Властивості: Varying densities and moisture content.
  • Придатність: Best cut with CO2 lasers.
  • Заявки: Меблі, декоративні предмети, custom projects.

• Paper and Cardboard:

• • Властивості: Thin and easily combustible.
  • Придатність: Best cut with CO2 lasers.
  • Заявки: Упаковка, вивіски, custom prints.

• Fabric and Textiles:

• • Властивості: Flexible and can be heat-sensitive.
  • Придатність: Best cut with CO2 lasers.
  • Заявки: Apparel, upholstery, Спеціальні дизайни.

• Пластмаса:

• • Властивості: Vary widely in melting points and chemical resistance.
  • Придатність: Best cut with CO2 lasers.
  • Заявки: Прототипування, споживчі товари, industrial components.

Ceramics and Composites:

• Кераміка:

• • Властивості: Hard, крихкий, and heat-resistant.
  • Придатність: Can be cut with Nd: YAG or fiber lasers.
  • Заявки: Електроніка, Медичні пристрої, industrial components.

• Композити:

• • Властивості: Vary based on the matrix and reinforcement materials.
  • Придатність: Can be challenging to cut; requires careful selection of laser parameters.
  • Заявки: Аерокосмічний, автомобільний, sports equipment.

Material Thickness

Thin Materials:

• Визначення: Generally considered to be materials up to 10 мм товщиною.
• Cutting Characteristics:

• • Ease of Cutting: Easier to cut with high precision and speed.
  • Heat Affected Zone (Хаз): Smaller HAZ, resulting in cleaner cuts.
  • Laser Type: CO2 lasers are often sufficient for thin materials, but fiber lasers can also be used for metals.

• Заявки: Sheet metal, thin plastics, папір, and textiles.

Thick Materials:

• Визначення: Generally considered to be materials over 10 мм товщиною.
• Cutting Characteristics:

• • Виклики: Requires higher power lasers and slower cutting speeds.
  • Heat Affected Zone (Хаз): Larger HAZ, which can affect the material’s properties.
  • Laser Type: Fiber lasers are preferred for thick metals, while Nd: YAG lasers can handle thick ceramics and composites.

• Заявки: Структурні компоненти, частини важкої техніки, thick plates.

Матеріальні властивості

Теплопровідність:

• High Thermal Conductivity: Materials like aluminum and copper conduct heat quickly, which can make cutting more challenging. Higher power and slower speeds are often required.
• Low Thermal Conductivity: Materials like plastics and wood retain heat more, allowing for faster cutting speeds.

Відбивна здатність:

• High Reflectivity: Reflective materials like aluminum, мідь, and brass can damage the laser if not properly managed. Fiber lasers are better suited for these materials due to their higher efficiency and lower risk of back-reflection.
• Low Reflectivity: Non-reflective materials like wood and plastics are easier to cut and pose fewer risks to the laser.

Точка плавлення:

• High Melting Point: Materials with high melting points, such as tungsten and molybdenum, require higher-power lasers and more precise control.
• Low Melting Point: Materials with low melting points, such as plastics, can be cut more easily and at higher speeds.

Хімічна стійкість:

• Chemically Resistant: Materials that are resistant to chemicals, such as PTFE (Тефлоновий), may require special considerations to avoid degradation during cutting.
• Chemically Sensitive: Materials that are sensitive to chemicals, such as certain plastics, may produce toxic fumes and require proper ventilation.

Special Considerations

Kerf Width:

• Визначення: The width of the cut made by the laser.
• Вплив: A wider kerf can affect the fit and finish of parts, especially in precision applications.
• КОНТРОЛЬ: Kerf width can be minimized by using higher-power lasers and optimizing cutting parameters.

Якість краю:

• Factors: The quality of the cut edge is influenced by the laser power, cutting speed, and assist gas.
• Improvement: Using the correct assist gas and maintaining a steady cutting speed can improve edge quality.

Material Deformation:

• Heat Affected Zone (Хаз): The area around the cut where the material has been heated but not melted can deform the material.
• Minimization: Using lower power and faster cutting speeds can reduce the HAZ and minimize deformation.

Fume and Dust Management:

• Fumes: Cutting certain materials, especially plastics and composites, can produce harmful fumes.
• Dust: Fine particles can accumulate and affect the cutting process.
• Рішення: Proper ventilation, dust collection systems, and personal protective equipment (ЗІЗ) є важливими.

9. Challenges and Limitations of Laser Cutting

Laser-cutting technology, while advantageous, also faces several challenges and limitations that can impact its effectiveness in certain applications.

Here are some key challenges to consider:

Material Limitations

Not all materials are compatible with laser cutting.

Some reflective metals, such as copper and brass, can reflect the laser beam, potentially damaging the cutting equipment and leading to poor cutting quality.

Додатково, certain plastics may emit harmful gases when cut with a laser, necessitating proper ventilation and safety measures.

Вартість міркувань

While laser cutting can be cost-effective in the long run due to reduced material waste and faster production times, the initial capital investment for high-quality laser-cutting machines can be substantial.

This cost barrier can be particularly daunting for small businesses or startups looking to implement advanced manufacturing technologies.

Technical Limitations

Laser cutting has limitations regarding the thickness of materials it can efficiently cut.

As material thickness increases, cutting speeds may decrease, resulting in longer processing times.

У багатьох випадках, traditional cutting methods, such as plasma or water jet cutting, may be more suitable for thicker materials, limiting the application of laser cutting in certain scenarios.

Heat-Affected Zones (Хаз)

The high-energy laser beam generates significant heat during the cutting process, leading to heat-affected zones (Хаз) around the cut edges.

These zones can alter the material properties, such as hardness and tensile strength, which may be critical for specific applications.

Managing HAZ is essential for industries where precise material characteristics are necessary.

10. Future Trends in Laser Cutting

Technological Advancements:

• Higher Power and Efficiency: Development of more powerful and efficient lasers.
• Improved Beam Quality: Enhanced beam control and focusing techniques.

Increased Automation:

• Robotic Systems: Integration of robotic arms for automated cutting processes.
• Розумне виробництво: Use of IoT and data analytics to optimize operations.

Стійкість:

• Eco-Friendly Practices: Adoption of eco-friendly materials and processes.
• Energy-Efficient Technologies: Development of energy-efficient laser systems.

11. Висновок

Laser cutting has become a cornerstone of modern manufacturing, пропонуючи неперевершену точність, ефективність, і універсальність.

Despite its initial costs and some limitations, the long-term benefits and technological advancements make it an invaluable tool for a wide range of industries.

Оскільки технології продовжують розвиватися, the future of laser cutting looks promising, with increased automation, стійкість, and innovation shaping the landscape of manufacturing.

We hope this guide has provided you with a comprehensive understanding of laser cutting and its significance in modern manufacturing.

Whether you’re a seasoned professional or just starting, the potential of laser cutting is vast and exciting.

If you have any laser-cutting processing needs, Будь ласка, не соромтеся Зв’яжіться з нами.