Focused Beam Cutting With Pre-Formed Chamfers and Low Oxidation
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Solution Overview
Problem
Conventional laser cutting methods require complex and costly mechanical post-processing of cut edges, such as rounding or creating chamfers, and are prone to oxidation and loss of coatings like zinc, especially in galvanized workpieces, leading to increased production time and costs.
Innovation Solution
A method using a focused machining beam to create troughs and gaps in workpieces before separation, adjusting focal position and power density to minimize mechanical post-processing, thereby producing workpieces with pre-formed chamfers and avoiding oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser cutting methods are used to cut workpiece parts from metallic workpieces, then automated production with high precision is enabled, but complex mechanical post-processing of cut edges is required
Solution Approach 1:
The patent applies preliminary action by creating a trough along the contour of the workpiece part before cutting. This pre-formed trough serves as a chamfer that eliminates the need for subsequent mechanical post-processing of the cut edges. The trough is created by moving the laser beam along the desired contour path, preparing the surface in advance so that when the part is cut, the edges are already properly formed for assembly operations like screwing or riveting.
2Manufacturing precision
If mechanical post-processing is performed on cut edges to round or chamfer them, then the workpiece parts are prepared for assembly, but production time and costs increase
Solution Approach 1:
The patent merges the contour preparation operation with the cutting operation into a single integrated process. Instead of performing separate operations for creating chamfers and then cutting, the trough is formed along the contour during the cutting process itself. This combination eliminates the need for separate mechanical post-processing steps, thereby reducing production time while maintaining the required cut edge quality for assembly operations.
3Productivity
If laser cutting with oxygen as working gas is used, then cutting speed is improved, but oxidation occurs at cut edges requiring grinding removal
Solution Approach 1:
The patent converts the harmful oxidation effect into a beneficial outcome by using the exothermic oxidation reaction to enhance the cutting process. The oxidation that would normally create unwanted oxide layers is harnessed to provide additional heat that facilitates faster cutting. The resulting oxide layer is then removed along with the trough material during the contour preparation, leaving clean edges without requiring separate grinding operations.
4Reliability
If zinc coating is present on workpieces before laser cutting, then corrosion protection is provided, but the zinc coating is lost at cut edges requiring re-galvanization
Solution Approach 1:
The patent applies preliminary action by creating the trough along the contour before the cutting operation. This pre-formed trough removes the zinc coating in advance in a controlled manner, exposing the base metal along the future cut line. When the cutting occurs, no additional zinc removal takes place at the edges, eliminating the need for re-galvanization. The trough itself can then be filled or sealed to restore corrosion protection at the cut edges.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables faster, more economical production of workpieces with pre-formed chamfers and reduced oxidation, eliminating the need for manual post-processing and subsequent coating, thus enhancing efficiency and reducing costs.
Implementation Method 1
a focused machining beam is directed at a first workpiece surface of the workpiece
Implementation Method 2
at least one trough is created in the workpiece... a gap is created in the workpiece
Data Source
AI summary
Methods, devices, apparatus, and systems are described for separating workpiece parts from workpieces using a focused machining beam. The methods include creating a trough in the workpiece using the focused machining beam, the trough being created along at least one section of a contour of the at least one workpiece part to be separated from the workpiece, altering a focal position of the machining beam such that the machining beam has a smaller beam diameter on the workpiece, and creating a gap in the workpiece using the machining beam with the altered focal position along at least one section of the contour of the at least one workpiece part to be separated from the workpiece. The gap is created at least partially within the trough.