Laser Flame Cutting With Deep Focus and Nozzle Gap for Thick Plates
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Solution Overview
Problem
Existing methods for flame cutting thick workpieces with high laser power do not achieve a corresponding increase in cutting speed, despite increased power, resulting in suboptimal cutting efficiency and edge quality.
Innovation Solution
Adjusting the focal position of the laser beam to be deeper within the workpiece, with a distance greater than half the workpiece thickness from the surface, and using a larger distance between the cutting gas nozzle and the workpiece surface, along with a Gaussian intensity profile and appropriate optical fiber configuration, to achieve increased cutting speed and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the focal position is arranged above or near the workpiece surface (conventional method), then the laser beam can effectively process thin workpieces and achieve fast cutting, but the cutting speed does not increase proportionally with laser power for thick workpieces
Solution Approach 1:
The patent changes the focal position parameter from above/near the surface to deep within the workpiece (more than half the thickness), and adjusts the nozzle distance parameter to at least 2mm. This parameter change enables efficient utilization of high laser power (>10kW) for thick workpiece cutting, achieving proportional increase in cutting speed with power increase.
2Manufacturing precision
If a large focal diameter is used for thick workpieces, then the cutting gap is wide enough to blow off liquefied material and slag, but the cutting speed decreases
Solution Approach 1:
The patent moves the focal position from the surface dimension to the depth dimension within the workpiece. This dimensional change allows the laser beam to create an elongated focal volume that simultaneously provides sufficient cutting gap width for material ejection and maintains high cutting speed through optimized energy distribution along the beam path.
3Reliability
If the nozzle distance is small (1-2mm as per conventional standards), then the cutting gas can effectively control the cut, but the cutting speed increases are limited even with higher power
Solution Approach 1:
The patent increases the nozzle distance parameter from the conventional 1-2mm to at least 2mm (preferably at least 3mm or 5mm). This parameter change, combined with the deep focal positioning, enables better cutting speed performance while maintaining process reliability through the synergistic effect of the modified process parameters.
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 a significant increase in cutting speed by up to 50% with 50% more laser power while maintaining good cutting edge quality and process reliability, contrasting with conventional methods that only saw a 20% increase in feed motion with 50% more power.
Implementation Method 1
a laser beam with a power of more than 10 kW
Implementation Method 2
a focal position in the beam direction of the laser beam is located or positioned within the workpiece at a depth that is greater than half the thickness of the workpiece
Implementation Method 3
flame cutting of a workpiece, in particular a planar workpiece, with a thickness of at least 10 mm by means of a laser beam with a power of more than 10 kW and with oxygen as a cutting gas
Implementation Method 4
the laser beam emerges from a nozzle opening of a cutting gas nozzle together with the cutting gas
Data Source
AI summary
A method for flame cutting of a workpiece, in particular a planar workpiece, with a thickness of at least 10 mm is performed by a laser beam with power of more than 10 kW and with oxygen as a cutting gas. Accordingly, a focal position in the beam direction of the laser beam is located within the workpiece at a depth that is greater than half the thickness of the workpiece. The laser beam emerges from a nozzle opening of a cutting gas nozzle together with the cutting gas, wherein a distance of a workpiece-side nozzle end face from the workpiece surface is at least 2 mm, preferably at least 3 mm, particularly preferably at least 5 mm.