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Laser Cutting Fundamentals

TRUMPF Inc.
A World Leader In Laser Technology

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

TRUMPF Laser Presentation


 Why Laser Processing
 Types of Light
 Types of Industrial Lasers
 CO2 Laser Theory
 RF - Excitation
 Laser Resonator Design
 The Cutting Process
 Processing Parameters
 Height Regulation System
 Cutting Techniques
 Difference in CO2 vs. Nd:YAG Lasers
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Why Laser Processing?


 Minimum set-up time
 Fast processing speeds
 High part tolerances
 Quality edges and finish
 No part distortion
 Flexibility and versatility
 Increased competitiveness
 Quiet
 Laser precautions
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Types of Light

Incandescent  Many different light


frequencies
 Diffused in all directions

Laser Beam

 Single light frequency


 In phase and same
direction

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Incandescent vs. Laser Light

Focused Power
1cm focal length
Measurement

100 Watt light bulb 0.08 Watts/cm2

100 Watt laser beam 800,000 Watts/cm2

0.013cm diameter

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

3 Basic Parts To Any Laser

 Excitation Method
 Gain Medium
 Optical Resonator

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Two Types of Industrial Lasers

 Gas Laser - CO2 as the Laser Medium


 10.6 µm wave length
 Powers up to 40,000 Watts
 Beam transmission with mirrors

 Solid State Laser - Nd:YAG as the Laser Medium


 1.06 µm wave length
 Powers up to 4,000 Watts
 Beam transmission with fiber optic cable

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

CO2 Laser Theory 4) Photon is emitted at


a high energy state
3) Energy level increases
from excitation and 5) CO2 molecule is
CO2
collisions cooled and brought
CO2 back to ground state
2) Add in excitation CO2
by He

CO2
N2

N2 He

N2 CO2 He Energy Levels


1) Molecules at ground state 6) Process repeats

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals
CO2 Laser Non-Lasing

N2 CO2

He

 Molecules at rest
 Gas mix ratio
 He (18)
 N2 (6)
 CO2 (1.5)
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Initial Lasing

N2
CO2

 Excited N2 molecules collide with excited


CO2 molecules
 Unstable CO2 molecules releases energy
by emitting a photon of light
 Photons bounce around in resonator
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals
Avalanche Effect (Stimulated Emission)

 Photons collide and emit other photons in the


same direction
 Eventually hit a mirror and reflect back
 Optics are aligned so photons bounce back
and forth
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Total Lasing (Light Amplification)

 Lasing occurs when photons are traveling


back and forth between the optics

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Laser Output (Radiation)


Front mirror
(output
Rear
coupler)
mirror

 Laser beam exits resonator through an


optical coupler
 The output optic is 60% reflective 40%
transmissive
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Electrode
Uniform Discharge
O-ring Electrode O-ring
Seal Seal
Gas In RF-excitation Gas Out

Anode Cathode
Discharge

O-ring O-ring
Seals Gas In Gas Out Seals
DC-excitation
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

RF- Excitation Benefits


 Low maintenance and high reliability of resonator
and optics
 Electrodes mounted external to discharge
 Fewer O-ring seals

 Mode stability
 Consistent mode throughout the power range

 Better efficiency
 Uses less laser gas

 Flexible power control


 High frequency pulsing

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Laser Resonator Optics

Linear Square
Folded

Maximum power
output depends on
the resonator length!

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

TRUMPF Laser Resonator Design


Bending Mirror

Turbo Pump

Gas Cooler

Frame

Rear Mirror

Output Mirror

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals
Beam Quality
I

 The beam quality influences Fundamental


Mode
the cutting performance TEM 00

 Thin and medium thick x

material cut best with a


I
TEM00 mode (Gaussian nearly
Fundamental
distribution) and narrow Mode
focussing TEM 00/01*
x

 For thick plate (above 0.75”)


a TEM01 mode (ring mode) I

is the optimum beam for best Ring Mode

cut quality TEM 01*


x

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals
Beam In
The Cutting Process
Lens

Assist Gas

Work piece Height


Regulation

Nozzle
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Before Cutting Begins


 90% of power is reflected
Reflected
 10% of power is absorbed laser
 Material melts immediately power

 Molten pool is called


“The Keyhole”

Absorbed laser power


(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

As the
Cutting Starts

 The Keyhole is blown away by the assist gas


 10% of power is reflected
 90% of power is absorbed
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Laser Cutting

 Cutting begins when


the beam is through
the material
 The beam, or
workpiece, or both,
must move to create
the desired cut path

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Processing Parameters

 Laser power
 Cutting speed
 Assist gas - type of gas, pressure
 Focus - length, position
 Nozzle - diameter, standoff
 Pulsing - frequency, time delay
 Piercing - time, power ramp, standoff

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Defining Process Parameters

 Material type
 Thickness
 Edge quality
 Other process parameters

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Types of Metal for Laser Cutting

 Mild Steel
 Aluminum
 Stainless
 Aerospace Alloys
 Coated Steels

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Types of Laser Power Control


 Pierce
 Start the cut
 Small hole drilling
 Continuous Wave (CW)
 Process cutting
 Pulse
 Small areas
 Reduce heat input

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Process Parameters
Cutting Gas
 Type
 O2 or N2 or shop air
 Pressure
 0 to 450psi
 Nozzle
 Hole size (more volume)
 Flow design
 Stand-off distance / length

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Process Parameters

Focus / Lens

 Focal length lens


 Stand-off distance
 Power density
 Working depth of field

 Focal height control systems

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Focal Length Definition

Spot diameter = 2D

Focal length = 2L
L

Spot diameter = D

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals
Capacitive Height Regulation System (DIAS III)
Z-position to NC/PLC
meas. system

Z-position meas. syst.

Digital outputs
DIAS III-System

Digital inputs

220 V
Z-drive

Nominal value Z-axis


Frequency meas. signal
Oscillator

Bitbus fiber-optics cable

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals
Laser Cutting Head 0001
5"D1,5"  HD

 Height Regulation
2
 DIAS insures a constant standoff
between nozzle and material
1 3
 Quick cutting head change
 Fast and precision adjustment by
means of micrometer screws and dial
indicator Serien­Nr.

1
0001

 Change of lenses or cutting head Ident­Nr.


256133

reduced to a minimum
 Nozzle cooled with compressed air

1 X adjustment screw with scale


2 Clamping pin
3 Y adjustment screw with scale
4 Nozzle 4
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Focal Height Control Systems


Ball Rollers
 Positive control method
 Rolls on material
 All materials
 Allows for multi-layer cut
 Simple design
 Difficult to process very close to
edge
 Flexible nesting nearly impossible
 Scratches on top of material
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Focal Height Control Systems


Spoon
 All materials
 Simple / Inexpensive
 Rides on material
 Difficult to process very
close to edge
 Flexible nesting nearly
impossible

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Machine System Configuration


 Sheet mover (tracker) - moving sheet in X and Y
 Hybrid - moving pallet in X only
 Flying optics - moving cutting head in X and Y
 Flat sheet or tube and pipe
 Multi-axis
 Robotics

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Maximum
Maximum Cutting Thickness(in(ininch)
Cutting Thickness inch)
0.9
0.8
0.7
0.6
aluminum
0.5
stainless
0.4
mild steel
0.3
0.2
0.1
0
TLF 1800 t TLF 2400 t TLF 3000 t TLF 3800 t

TRUMPF RF-excited Laser Resonator


TRUMPF RF-excited Laser Resonator
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Cutting Rules of Thumb for Mild Steel


 Gas type
 Oxygen
 Pressure
 10 to 60 psi
 Nozzle
 0.040” dia.
 Focus lenses
 5” or 7.5”
 Speed / Power relationship

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Other Cutting Techniques

 High pressure cutting


 Air / Inert gas up to 450 psi
 Oxide-free surface edge

 Thick material cutting


 Longer focal length lens
 Lower gas pressure

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Quality Cutting Goes Beyond Process Parameters


 Beam Quality / Stability
 Best focus ability
 Optimizes parameters
 Best part quality Re-alignment
 Smallest nozzle diameter
− Closer to material
− Less gas consumption
 Reliable process results
Downtim
 Beam Delivery System e
 External mirror maintenance
 Mirror alignment
 Lens removal and alignment

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Quality Cutting Goes Beyond Process Parameters


 Assist Gas Quality
 Gas purity
 Reliable gas flow

 System Performance
 Smooth accurate motion system
 Interface and control
 Reliability

 Material Quality
 Carbon steels
 Rust and scale
 Grease penciled or painted material
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Cutting of Small Holes


 Cutting in pulse mode
with a frequency of 10Hz
 Diameter smaller than
material thickness
 High accuracy of contour

Ø = 0.2 in.

Example: Material Mild steel


Material thickness 0.5 in.
Smallest hole diameter 0.4 in. x thickness
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

SprintLas - Increase in Productivity: 40 - 50%


®

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Machine: L3030 Material thickness: 0.060 in


Laser: TLF 3000t Cutting time w/out SprintLas : 78 s ®

Material: Mild steel Cutting time with SprintLas : 43 s ®

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

ToPs 100: Programming System for Lasers


 Geometry data input from
CAD-systems (DXF, IGES, ...)
 Integrated Know-How:
 Cutting parameters (SprintLas,
common line, ...)
 Technology tables

 Job-related nesting; "true shape"


or “rectangular” nesting processor
 Automatic processing definition
 Automatic collision check

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Difference in CO2 vs. Nd:YAG Lasers


 Gain Medium
 Excitation Methods
 Resonator Design
 Difference between CO2 & Nd:YAG
 Operating Costs
 Applications - Cutting
 Applications - Welding
 Choosing between CO2 & Nd:YAG
 Future Developments
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals
Excitation Methods

Electrode

CO2 Discharge

Electrode
Electrical
Gas In Gas Out

Discharge
Nd:YAG
Light
(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)
Laser Cutting Fundamentals

Resonator Designs

CO2

Nd:YAG

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Differences Between CO2 & Nd:YAG

 Maximum output power / Pulsing


 Mechanical
 Wavelength
 Beam Quality / Focus ability
 Maintenance / Reliability / Consumables
 Application

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Operating Costs
3000 W - CO2 3000 W - Nd:YAG
 Laser Gases  Flash lamps
 Process gas (welding)  Ion Exchanger
 Beam delivery purge /  Protection glass
components
 Maintenance /hour
 Maintenance /hour
 Electrical
 Electrical
 Total cost per hour $12
 Total cost per hour $10

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Applications - Cutting

CO2 Nd:YAG
 Sharper edge  Smooth cut edge
 Fast cut speeds  Cuts highly reflective
materials copper, silver,
 Can cut up to 1 inch
gold
thick mild steel
 Best in metals < 1.0mm
 Best in metals > 4.0mm

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Applications - Welding
CO2 Nd:YAG
 Best in deep penetration  Faster in thinner
welds materials (<1.0mm)
 Good for mild and  Absorption in Aluminum
Stainless Steel is 12% to 80%
 Absorption in Aluminum is
5% to 62%
 Can use longer focal
length lens

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Choosing Between CO2 & Nd:YAG

 Look at the application first

 Weigh the importance of each lasers’ characteristics

 Consider overall costs and not just initial purchase

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)


Laser Cutting Fundamentals

Future Developments
 The gray area between CO2 and Nd:YAG will
increase as YAG’s increase in power
 Flexible cable for lower power CO2 beam delivery

 Diode pumped Nd:YAG lasers (eliminates flash


lamps)
 40 kW CO2 lasers with cut beam quality

(TAI 11/11/98 - Laser-Fundamentals-V1.ppt - 23/AS)

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