Beam Kerf Post-Processing for Laser-Cut Plate and Tube Edges
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Solution Overview
Problem
The production of metal workpiece parts using laser cutting is labor-intensive and costly due to the need for complex post-processing of cut edges, oxidation issues, and loss of zinc coating, leading to time-consuming and expensive mechanical processing.
Innovation Solution
A process that uses a jet machining technique to partially cut workpieces, allowing for automated and cost-effective production by creating a cutting gap along the contour of the workpiece part, enabling non-separating post-processing along the kerf to address edge quality and coating issues without fully separating the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser cutting is used to cut workpiece parts from plate-shaped or tubular workpieces, then automated production with high precision is enabled, but complex mechanical post-processing is required for cut edges
Solution Approach 1:
The patent combines the cutting operation with post-processing operations into a single integrated laser beam process. The laser beam performs both cutting and subsequent edge treatment (rounding, chamfering, burr removal, oxidation removal) without requiring separate mechanical post-processing equipment, thereby reducing device complexity while maintaining automated production
Solution Approach 2:
The laser beam is used for multiple functions: cutting the workpiece, rounding edges, creating chamfers, removing burrs, and eliminating oxidation. This multi-functionality eliminates the need for multiple specialized mechanical post-processing tools, reducing overall system complexity while preserving automated production capabilities
2Manufacturing precision
If mechanical post-processing is performed on cut edges, then edge quality is improved, but production time and costs increase
Solution Approach 1:
The laser beam continues its action from cutting directly into post-processing without interruption or transfer to mechanical tools. The beam moves continuously along the cut path, first cutting the workpiece and then immediately performing edge treatment operations, eliminating idle time and transfer time between processes while maintaining high edge quality
Solution Approach 2:
The post-processing actions are performed immediately after cutting while the workpiece is still in position and the laser head is already at the correct location. This preliminary treatment of edges prevents the need for additional handling and setup time that would be required if mechanical post-processing were performed separately
3Productivity
If oxygen is used as working gas for laser cutting, then cutting efficiency is improved, but oxidation occurs on cut edges requiring additional grinding
Solution Approach 1:
The patent converts the harmful oxidation effect into a beneficial process by using the same laser beam and oxygen atmosphere that cause oxidation to subsequently remove the oxidation. The laser heats and vaporizes the oxide layers formed during cutting, transforming the harmful oxidation into a self-correcting process that eliminates the need for additional grinding operations
4Productivity
If galvanized workpieces are laser cut, then production is enabled, but zinc coating is lost in the cutting gap area requiring regalvanizing
Solution Approach 1:
The laser beam applies localized heating precisely where needed - in the cutting gap area where zinc coating is lost. By concentrating energy only in the affected zones rather than treating entire workpiece surfaces, the process efficiently restores coating adhesion properties without excessive energy consumption or affecting areas that don't require treatment
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 process reduces the need for extensive mechanical post-processing, saves time and costs, and allows for efficient production of workpiece parts with improved edge quality and coating retention, enhancing the automation and efficiency of the manufacturing process.
Implementation Method 1
the workpiece is machined to produce a cutting gap by a processing beam (16) guided by a beam head (3)
Implementation Method 2
the workpiece is reworked along at least part of the cutting gap by a machining beam
Data Source
Figure 1~3
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Figure 7~9
AI summary
The invention relates to a process for the blasting machining of a plate-like or tubular workpiece (9), comprising a) at least one separating procedure for creating a cutting gap (15) along a cutting line (14) that extends at least partially along the contour of a workpiece part (11) to be produced from the workpiece (9), wherein the separating procedure comprises: moving a blasting head (3), which serves for guiding a machining jet (16), over the workpiece (9), wherein the machining jet (16) is guided along the cutting line (14) from a first cutting position to a second cutting position, and wherein the machining jet (16) has a first power density, which is rated such that workpiece is severed, b) at least one post-machining procedure for post-machining the workpiece (9) along at least a part of the cutting gap (15), wherein the workpiece part (11) is not entirely cut out, wherein the post-machining procedure comprises: moving the blasting head (3) over the workpiece (9), wherein the machining jet (16) is guided along a post-machining line (18) from a first post-machining position to a second post-machining position, wherein the machining jet (16) has a second power density, which is rated such that the workpiece (9) is not severed, and wherein the workpiece (9) is blasted by the machining jet (16) along at least a part of the cutting gap (15) in a region containing a workpiece-part-side cutting edge (19) of the cutting gap (15) and/or in a region containing a skeleton-side cutting edge (19) of the cutting gap (15).