Laser cutting and bending of metal

"Robodynamics" specializes in providing metalworking services, including laser cutting and bending. During the process of laser cutting sheet metal, advanced, highly efficient equipment is used. This process allows for cost optimization in the manufacture of components in both small and large volumes. Cutting is performed in an environment of gaseous nitrogen and oxygen, which eliminates the possibility of defects appearing on the cut edges and significantly improves the quality of the weld seam.

LASER CUTTING OF THICK METAL

Laser cutting is a technology that involves direct action on the material surface with a directed laser beam, which melts and burns the metal, providing neat cutting without the need for additional processing. This is achieved due to the properties of the laser beam: high precision, stability, and power.

However, incorrect use of technology or the use of low-quality raw materials and equipment can lead to defects. The most common ones are the formation of burrs and uneven edges when cutting thick metal. This can happen due to incorrect cutting speed or incorrect cutting angle of the machine. The appearance of vortices and grooves on the cut is also related to the features of laser cutting technology and can be prevented by correctly setting the parameters of the equipment.

Cutting thick sheet metal requires increased laser radiation power, which can slow down the process and cause the formation of burrs and roughness. In addition, when processing parts with a high ratio of thickness to cutting width, difficulties may arise, as a result of which the edges may turn out to be uneven.

The photos show laser cutting defects such as roughness and burrs:

— on 5mm (a) and 16mm (b) stainless steel;

— on 30mm titanium (c);

— on 0.5mm electrical steel (d);

— on 5mm stainless steel (e), where the lower part of the cut is oxidized due to the addition of air;

— on 1mm stainless steel (f).

FEATURES OF CUTTING THICK SHEET METALS

The quality of cutting and the potential for defects in laser processing of thick metal significantly depend on the physicochemical properties of the alloy. For example, when cutting cold-rolled steel sheets with low carbon content under the influence of intensive thermal exposure, the edges of the metal become softer. If the part is subjected to further processing, this is not a problem. However, in alloys with a high concentration of carbon, even a short-term effect of a laser leads to hardening of the cut, forming a hardened section of steel. If the goal is to strengthen the edge of the part and increase its mechanical characteristics, this 'defect' becomes an advantage. If further processing of the part is required, its excessive hardness can provoke the formation of microcracks, undermining the structure of the material.

Choosing an individual cutting mode for each separate type of alloys can help minimize the risk of noticeable defects when cutting thick metals.

Photos of the shape of laser cut channels in cross-sections relative to the direction of movement of the laser source:

— a, b - titanium, thickness 10 mm, CO2 laser with a power of 4 kW, focal length 254 mm, channel width at half thickness 330 microns (a), focus depth 9 mm, (a) and 19 mm (b), pressure 5 atm;

— c - stainless steel, thickness 10 mm, focus depth 13 mm;

— d - austenitic stainless steel AISI 304, thickness 6 mm.

The photos demonstrate the surface relief of low-carbon steel processed with a CO2 laser with a power of up to 5 kW under different conditions. Traditional laser cutting with oxygen (a, b, c, d) and hybrid oxygen cutting with laser radiation support (e) were compared.

Sheet thickness L: 5 mm - a, b; 16 mm - c, d; 25 mm - e.

Cutting speed Vc: 1.6 m/min - a; 1.5 m/min - b; 1.0 m/min - c; 0.6 m/min - d; 0.27 m/min - e.

Excessive pressure was applied:

— 1.0 atm: a, b

— 0.3 atm: c, d

— 6.0 atm: e

ALLOY STEELS

The process of laser cutting alloys, alloyed with steel, depends on the amount of alloying elements they contain. The fewer such elements, the easier the cutting is. However, when there is a large number of alloying elements, the viscosity of the metal increases, which causes intensive oxidation of the metal on the cut, changing its color and the appearance of noticeable irregularities. During the cutting process of such alloys, martensite is formed - a layer of hardened steel on the edge of the processed part, which requires additional fine-tuning of the cutting parameters.

ALUMINUM

Laser cutting of aluminum is a complex process due to the high reflectivity and thermal conductivity of this metal. Prolonged exposure can cause microcracks, reducing the strength of the parts and potentially leading to their premature destruction. Removing the damaged layer can lead to a reduction in part size and an increase in cutting costs. Therefore, laser cutting of aluminum is usually used in the production of parts and structures for "ground" machinery, where small deviations in size are not critical.

TITANIUM

Laser processing of titanium requires the replacement of oxygen and nitrogen with inert gases, such as helium and argon. These gases do not react with the metal, preventing the appearance of many defects on the cut. Argon is often chosen because of its low cost, however, its use can lead to a reduction in the strength of the titanium alloy and, as a result, the entire product. To prevent such problems, a gas mixture of argon and helium can be used in a ratio of 1:1 or 1:4, which improves cutting quality and reduces the likelihood of part damage.

ADVANTAGES OF WORKING WITH ROBODYNAMICS

Large park of laser and bending equipment - allows for large orders.

Qualified technical and production staff - equipment setup is carried out in a short time, material is used as efficiently as possible, reducing costs.

High precision of manufactured parts.

Robodynamics' quality management system meets the requirements of the ISO 9001:2015 standard. Robodynamics' environmental management system meets the requirements of the ISO 14001:2015 standard.

Modern software for optimizing material consumption during cutting - reducing the price.

METAL BENDING

The process of bending metal in industrial conditions allows us to give metal blanks the required shape, creating volumetric parts or elements. With modern CNC machines, we manage to minimize the percentage of rejects, simplify the production procedure and reduce the cost of finished products. Moreover, as a result of metal bending, the products are seamless, which ensures their resistance and long service life. CNC machines allow us to form any shapes from metal according to the client's wishes and apply various decorative elements.

We work with materials such as:

— copper;

— aluminum;

— brass;

— steel and other alloys.

We also process materials protected by film, which excludes the possibility of damaging the blank surface. The film can be removed when the product is completely ready, which guarantees the preservation of its appearance.

LASER CUTTING OF PIPES

Laser processing of pipes is an innovative approach to metalworking, in which a laser beam, following a pre-set trajectory, creates a thin and even cut line, separating parts of the material. During this procedure, a jet of gas is supplied to the cutting area, providing cleaning and cooling of the edge. This work is performed on specialized equipment equipped with a laser device. Thanks to the use of a laser cutting machine, the highest precision and consistency of the cut can be achieved.

The application of laser pipe cutting technology provides a replacement for several traditional technological operations, such as sawing, cutting, drilling, milling, and edge processing.

Laser pipe cutters represent a key technology for cutting pipes of various shapes, including square, round, and specialized. Their stability and cutting accuracy make them indispensable in many industries, such as:

— metalworking field;

— automotive industry;

— oil industry;

— petrochemical industry;

— aviation industry;

— mining industry;

— construction.

Traditional methods of pipe cutting include:

— cutting using a hand saw;

— processing on a milling machine;

— using a band saw for cutting;

— using an abrasive cutoff machine;

— cutting with gas welding and so on.

Often these technologies turn out to be not enough effective and require a lot of labor compared to combined and fiber-optic laser pipe cutters.

HIGH-POWER LASER CUTTING TECHNOLOGY

A high-power laser focuses its energy on a minimal diameter area, selectively affecting the metal and turning it into a molten state. The productivity of this process surpasses all alternative methods, thanks to the ability of the laser machine to cut a pipe with a wall thickness of up to 6 mm in just one minute.

The transition between different products occurs automatically, without the need for auxiliary equipment reconfiguration. High cutting purity along the edge of stainless steel or copper alloy pipes is achieved by using high-precision equipment. This parameter plays a critically important role in pipeline production, where the purity of the cut determines the ability of the final structure to withstand intensive loads and high pressure.

Both regular and decorative laser cutting of copper pipes stand out not only for their absence of deformation, but also for the complete preservation of the original product characteristics, as the metal is not overheated during cutting. Laser cutting offers high quality, ensuring cutting precision combined with high work speed. The pipe edge does not require additional processing, the cut line is smooth and neat.

ADVANTAGES AND DISADVANTAGES OF LASER PIPE CUTTING

Laser pipe cutting offers a unique set of advantages:

Execution of complex and figurative contours without direct contact with the processed pipe;

Formation of hinge and disconnecting connections, providing convenience and flexibility during assembly;

Creation of various grooves and holes, which expands the possibilities of automating subsequent processes and increases productivity;

Positioning elements for welding, which increases the accuracy and quality of welding connections;

Absence of thermal deformations, which preserves the integrity and shape of the processed parts;

Minimal material losses due to high cutting precision;

Creation of clean, complex, and accurately repeatable cuts;

Ability to work with most metallic and some non-metallic materials;

Ability to process most types of pipe blanks.

Note the following limitations or issues associated with laser tube cutting:

Materials that easily ignite or emit smoke, such as acetal or PVC, cannot be used;

This process requires significant energy consumption;

Laser control is a complex task that requires special training for operators;

Mainly, laser cutting is suitable for processing thin materials, no thicker than ½-1 cm.

MATERIAL AND MAXIMUM WORKPIECE SIZES

Maximum workpiece sizes:

— for round pipes - up to 220 mm in diameter;

— for profile rectangular pipes - up to 220 mm on the maximum diagonal;

— standard workpiece length - 6400 mm.

Minimum production waste – 200mm – 200мм

Material:

— carbon steel

— stainless steel

— other non-ferrous metals (copper, galvanized steel, etc.)

Maximum length of the finished part - 6200 mm. – 6200 мм

OUR EQUIPMENT

Our company is equipped with high-quality Raycus laser machines, two units in total. These machines allow us to process sheets up to 1500x3000 mm with a laser power of 2.5 kW and 6.5 kW. The accuracy of manufacturing reaches H14 h14, which guarantees perfect accuracy in work.

The maximum thickness of processed metal is 25 mm for carbon steel, 12 mm for stainless steel, and 8 mm for aluminum.

In addition to our laser machines, we also own two bending machines. They allow bending parts with a maximum length of up to 3000 mm and a thickness of up to 10 mm, at a maximum force of 175 ts. This equipment ensures high precision and efficiency in the manufacture of parts of varying complexity.

COST CALCULATION

To get an accurate calculation of the cost of metal laser cutting services, we ask you to provide the following information to our sales department:

— Drawings of the necessary parts, preferably in DWG format.

— If possible, a mathematical (3D) model. We recommend using DXF file format.

— The number of parts that need to be manufactured.

— The desired manufacturing time.

This information will help us provide you with the most accurate and current cost calculation.

COST

Laser cutting of carbon steel from 20 rubles per meter. от 20 руб. за 1 метр.

Laser cutting of non-ferrous metals from 80 rubles per meter. от 80 руб. за 1 метр.

The minimum order size is 10,000 rubles. — 10 тыс. рублей.

DELIVERY AND DETAILS

We ensure fast and reliable delivery of orders throughout Russia. быструю и надежную доставку заказов по всей территории России.

E-mail: lazercut@robodinamika.ru

Do you have any questions?