Convergent Nozzle Setup for Collision-Resistant Laser Fusion Cutting
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Solution Overview
Problem
Laser fusion cutting methods are susceptible to nozzle collision with tilted workpieces due to the close distance between the nozzle and the workpiece surface, leading to reduced process reliability and increased risk of disruption.
Innovation Solution
A convergent nozzle with a small nozzle channel diameter and a larger process distance (2-8 mm) between the nozzle end face and the workpiece surface, combined with a high cutting gas pressure (15-30 bar), reduces the risk of collision and maintains kerf coverage, allowing for high cutting speeds and increased productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the distance between the nozzle end face and the workpiece surface is reduced to minimize gas consumption, then gas consumption is reduced, but the risk of nozzle collision with tilted workpiece parts increases
Solution Approach 1:
The patent changes the key parameter of nozzle-to-workpiece distance from the conventional 0.5 mm to a range of 2-8 mm. This parameter change reduces gas consumption by expanding the gas distribution pattern over a larger area, while simultaneously reducing collision risk by increasing the clearance between the nozzle and workpiece surface.
2Area of stationary object
If the nozzle channel diameter is reduced to minimize disrupting contour, then the disrupting contour is reduced, but the kerf coverage by cutting gas may be insufficient
Solution Approach 1:
The patent optimizes the nozzle channel diameter to a specific range of 1.5-4 mm, which balances the need for a small disrupting contour with adequate kerf coverage. This parameter optimization ensures that the cutting gas is distributed effectively across the kerf width while maintaining a compact nozzle profile.
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
The method achieves a small disrupting contour, reduces collision risk, and enhances process reliability, enabling high-speed cutting of large workpieces with improved productivity and reduced gas consumption.
Implementation Method 1
a laser beam and a cutting gas, in particular nitrogen, at a cutting gas pressure are directed at the workpiece surface
Implementation Method 2
the material of the workpiece is melted to form a kerf
Implementation Method 3
the material of the workpiece is melted to form a kerf and is evacuated in liquid form from the kerf by means of a cutting gas
Implementation Method 4
a cutting gas pressure of 15 to 30 bar
Data Source
AI summary
In a method for laser fusion cutting in particular a plate-shaped workpiece, preferably with a thickness D of at least 1 mm, a laser beam and a cutting gas, in particular nitrogen, at a cutting gas pressure are directed at the workpiece surface by a convergent cutting nozzle. The laser power is at least 6 kW and the cutting nozzle has a nozzle end face on the workpiece side. A distance A between the nozzle end face and the workpiece surface during the cutting operation is 2 to 8 mm. The cutting nozzle has a nozzle channel with a diameter dD at the nozzle end face on the workpiece side of 1.5 to 4 mm. The cutting gas pressure before emergence from the cutting nozzle is 15 to 30 bar. This makes it possible to achieve high productivity along with a reduced risk of collision, i.e. higher process reliability.