Beam Edge Finishing for Laser-Cut Plate and Tube Workpieces
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Solution Overview
Problem
Existing laser cutting processes for metallic workpieces require extensive mechanical finishing, including edge rounding, burr removal, and oxide layer removal, which are time-consuming and costly, especially for galvanized materials, prolonging production time and increasing costs.
Innovation Solution
A process that integrates cutting and non-cutting finishing operations using a single beam, where a processing beam creates a cutting gap and finishes the edges of the workpiece in a single automated step, reducing the need for separate mechanical finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser cutting is used to cut workpiece parts from metallic workpieces, then cutting precision and automation are improved, but extensive mechanical finishing is required for cut edges
Solution Approach 1:
The patent combines cutting and edge finishing operations into a single integrated process. The laser beam performs both cutting through the workpiece and subsequent edge finishing (rounding, chamfering, burr removal) without requiring separate mechanical finishing steps, thereby resolving the contradiction between high cutting precision and the need for extensive post-processing
Solution Approach 2:
The laser beam is used for multiple functions: cutting, edge rounding, chamfering, and burr removal. This multi-functional approach eliminates the need for separate mechanical finishing equipment and operations, addressing the contradiction by making the cutting process itself capable of producing finished edges
2Manufacturing precision
If mechanical finishing is performed on cut edges, then edge quality is improved, but production time and costs increase
Solution Approach 1:
The laser beam continuously performs both cutting and edge finishing in one uninterrupted operation. The beam transitions seamlessly from cutting mode to finishing mode, maintaining continuous useful action without stopping for separate mechanical finishing steps, thereby improving productivity while maintaining edge quality
Solution Approach 2:
The patent replaces mechanical finishing systems with a laser-based finishing process. The laser beam performs edge rounding, chamfering, and burr removal through thermal processing rather than mechanical contact, eliminating the need for mechanical finishing equipment and reducing production time
3Productivity
If oxygen is used as working gas during laser cutting, then cutting speed is improved, but oxidation occurs at cut edges requiring additional processing
Solution Approach 1:
The patent converts the harmful oxidation effect into a beneficial process by using the laser beam to intentionally create controlled oxide layers during cutting. These oxide layers are then immediately reduced or removed by the continuous laser action, transforming the harmful oxidation into part of the cutting and finishing process itself, thereby maintaining cutting speed while eliminating the need for separate oxide removal steps
4Productivity
If galvanized workpieces are cut by laser, then production efficiency is improved, but zinc coating is lost at cutting edges requiring re-galvanization
Solution Approach 1:
The patent performs edge finishing with the laser beam immediately after cutting, before the zinc coating can be lost or deteriorate. The continuous laser action seals or protects the edges during the finishing process, preventing zinc loss and eliminating the need for subsequent re-galvanization, thereby maintaining production efficiency while preserving the coating
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
This approach allows for faster, more economical production of workpiece parts by automating the finishing process, saving time and costs, and enabling efficient edge preparation without separate mechanical intervention.
Implementation Method 1
a cutting procedure for creating a cutting gap along a cutting line by heating and melting the workpiece with the processing beam guided by the beam head
Implementation Method 2
heating and melting the workpiece with the processing beam
Implementation Method 3
a finishing procedure for finishing the workpiece along at least a portion of the cutting gap by heating and melting the workpiece with the processing beam guided over the workpiece
Implementation Method 4
heating and melting the workpiece with the processing beam
Data Source
AI summary
Processes, devices, and systems for beam processing of plate-shaped or tubular workpieces are provided. The processes include: a) carrying out at least one cutting procedure for producing a cutting gap along a cutting line that extends at least partially along a contour of a workpiece part to be produced from the workpiece, and b) carrying out at least one finishing procedure for finishing the workpiece along at least one part of the cutting gap, during which the workpiece part is not completely cut out. The cutting procedure includes moving a beam head for guiding a processing beam above the workpiece along the cutting line from a first cutting position to a second cutting position. The finishing procedure includes moving the beam head over the workpiece, and the processing beam is guided along a finishing line from a first finishing position to a second finishing position.