Laser Beam Vibration for High-Speed Stainless Steel Cutting
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Solution Overview
Problem
Laser machining of stainless steel sheet metal with a thickness of 3 mm or more using a 1 μm laser beam often results in narrow kerf widths, leading to machining defects due to insufficient molten metal discharge, and increasing laser power is not energy-efficient.
Innovation Solution
A laser machining apparatus and method that vibrates the laser beam in a parallel direction with the cutting advancing direction, using a specific vibration frequency and moving velocity optimized for each plate thickness to maintain a suitable kerf width for efficient molten metal discharge and high-speed cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the focus point is located on the top surface of the sheet metal, then the kerf width is narrow, but the molten metal cannot be discharged properly causing machining defects
Solution Approach 1:
The patent applies mechanical vibration to the laser beam in the parallel direction with the cutting advancing direction. This vibration widens the kerf width by causing the laser beam to oscillate laterally, allowing molten metal to be discharged more effectively from the narrow kerf while maintaining precise cutting width control through controlled vibration parameters.
Solution Approach 2:
The patent employs periodic vibration of the laser beam at specific frequencies and amplitudes. This periodic action creates rhythmic widening of the kerf width, enabling periodic discharge of molten metal blocks that would otherwise clog the narrow kerf, thereby ensuring continuous and reliable machining.
2Manufacturing precision
If the focus point is located above or below the top surface to widen the kerf width, then the kerf width increases, but the energy density decreases and cutting velocity becomes low
Solution Approach 1:
By vibrating the laser beam in the parallel direction with cutting advancing direction, the patent achieves kerf width enhancement without defocusing. The vibration amplitude and frequency are controlled to widen the effective kerf width while keeping the focus point on the top surface, thereby maintaining high energy density and cutting velocity.
Solution Approach 2:
The patent introduces dynamic vibration to the otherwise static focusing system. By making the laser beam position dynamic through vibration while maintaining the focus point on the top surface, the system achieves both widened kerf width for molten metal discharge and maintained energy density for high cutting velocity.
3Productivity
If laser power is increased to increase cutting velocity, then the cutting velocity increases, but energy consumption increases which is not energy efficient
Solution Approach 1:
The patent uses mechanical vibration of the laser beam to enhance cutting performance without increasing laser power. The vibration facilitates molten metal discharge and prevents clogging, allowing efficient cutting at lower power levels, thereby improving energy efficiency while maintaining or increasing cutting velocity.
Solution Approach 2:
The patent changes the vibration parameters (frequency and amplitude) of the laser beam to optimize cutting performance. By adjusting these parameters, the system achieves efficient molten metal discharge and high cutting velocity without needing to increase laser power, thus maintaining energy efficiency.
4Manufacturing precision
If vibration frequency and moving velocity are not optimized, then the cut surface quality deteriorates, but optimizing for each plate thickness requires systematic consideration
Solution Approach 1:
The patent establishes systematic relationships between vibration frequency, moving velocity, and plate thickness through experimental data and theoretical analysis. These relationships provide feedback guidelines for selecting optimal parameters, reducing the complexity of parameter optimization while ensuring high cut surface quality for different plate thicknesses.
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 high-speed cutting of stainless steel with a good quality cut surface by maintaining a low viscosity of molten metal and ensuring effective discharge, outperforming conventional methods in terms of speed and surface quality.
Implementation Method 1
vibrating the laser beam in a parallel direction with the cutting advancing direction within a kerf width of the sheet metal
Implementation Method 2
a laser machining apparatus that cuts sheet metal by laser beams emitted from laser oscillators
Implementation Method 3
the wavelength of the laser beam emitted by a CO2 laser oscillator is approximately 10 μm, while the wavelength of the laser beam emitted by a fiber laser oscillator or a DDL oscillator is approximately 1 μm
Data Source
AI summary
A machining head emits a laser beam for cutting sheet metal of stainless steel. A moving mechanism moves the machining head relatively to a surface of the sheet metal. A beam vibrating mechanism vibrates a laser beam in a parallel direction with a cutting advancing direction of the sheet metal. In a machining condition database, a single specific vibration frequency at which cutting of the sheet metal is possible is set to a maximum moving velocity at which cutting of the sheet metal is possible, and a plurality of vibration frequencies from a maximum frequency to a minimum frequency at which cutting of the sheet metal is possible are set to a moving velocity more than or equal to a minimum moving velocity and less than the maximum moving velocity at which cutting of the sheet metal is possible.