Laser Cut-Edge Rounding for Plate and Tube Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing metallic workpiece parts require extensive and costly mechanical post-processing to round, chamfer, or countersink cut edges, which is time-consuming and inefficient.
Innovation Solution
A two-step method using a processing beam comprising a laser beam and process gas to create a cutting gap and a rounding, chamfer, or countersink zone on metallic workpieces, with different gases and energy settings for each step to automate and enhance the precision of edge modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser cutting is used to separate workpiece parts, then cutting speed and automation are improved, but extensive manual post-processing is required for edge modification
Solution Approach 1:
The patent combines the cutting process and edge modification process into a single integrated laser processing operation. The processing beam performs both separation (cutting) and modification (rounding, chamfering, countersinking) in one automated pass, eliminating the need for separate manual post-processing steps and significantly reducing total production time
Solution Approach 2:
The laser processing beam is configured to perform multiple functions: it can separate workpiece parts through cutting, round cut edges, create chamfers, and produce countersinks. This multi-functional capability allows a single processing system to replace multiple specialized tools and operations, improving both productivity and reducing post-processing requirements
2Manufacturing precision
If mechanical post-processing is used to round, chamfer, or countersink cut edges, then edge quality is improved, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent replaces mechanical post-processing tools (such as grinding wheels, chamfering tools, and countersinking devices) with a laser processing beam. The laser provides non-contact, automated edge modification with high precision, eliminating the need for multiple mechanical tools and manual operations while maintaining or improving edge quality
Solution Approach 2:
The laser processing parameters (power, speed, focal position, gas flow) are dynamically adjusted to achieve different edge modification outcomes (rounding, chamfering, countersinking) and maintain optimal edge quality across varying workpiece materials and thicknesses. This parameter control ensures high manufacturing precision while keeping the process automated and efficient
3Device complexity
If separate cutting and post-processing operations are used, then process control is simplified, but total manufacturing time and cost increase
Solution Approach 1:
The patent merges cutting and edge modification into a single integrated laser processing operation with unified control. The processing beam transitions between separation mode and modification mode within one automated sequence, reducing the number of setup changes and control transitions compared to separate operations, while dramatically reducing total manufacturing time
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 automated, faster, and more cost-effective production of workpiece parts with high-quality rounded, chamfered, or countersunk edges, reducing the need for manual post-processing and lowering manufacturing costs.
Implementation Method 1
a first section of a cutting gap is created in a first section of a cutting line by means of a laser beam which is guided along the cutting line
Implementation Method 2
the laser beam and a process gas exit together from a nozzle... either a cut is made first... with a first processing beam... thereby creating a cutting gap
Implementation Method 3
a processing beam comprising a laser beam and process gas for ejecting molten workpiece material
Implementation Method 4
a second section of the cutting gap is created... by means of a second processing beam... thereby creating a rounding zone, chamfer zone or countersink zone
Data Source
Figure 1
Figure 2~4
Figure 5~7
AI summary
The invention relates to a method for processing a plate- or tube-shaped workpiece (9) with a processing beam (26) comprising a laser beam (16) and a process gas (25), which is directed onto a workpiece surface (17) for processing the workpiece (9), wherein the workpiece (9) is processed in a first processing step with a first processing beam (26) guided along a cutting line (14, 37), thereby creating a cutting gap (15) in the workpiece (9) extending through the thickness of the workpiece, which extends in length along the cutting line (14, 37) and is limited in width by two cutting edges (19, 19') in the workpiece (9), and wherein the workpiece (9) is processed in a second processing step with a second processing beam (26) which is guided along a post-processing line (18, 44) or zone (22) that runs parallel and offset to one of the two cutting edges (19, 19').This creates a rounding zone (34), chamfer zone (21), or countersink zone (21) on the workpiece (9) in the area of this cutting edge (19, 19'). It is essential that the first processing jet (26) contains a different process gas (25) than the second processing jet (26).