Laser Cutting Intersecting Apertures for Edge Quality
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Solution Overview
Problem
Conventional workpiece processing machines require multiple perpendicular grid-like inner cuts to form shapes, which is inefficient and results in lower quality edges due to larger residual workpiece segments that can affect processing quality.
Innovation Solution
The method involves forming intersecting apertures in a workpiece using a laser beam along intersecting line paths and cutting out a shape by moving the laser beam along a continuous final path extending around the intersection point, reducing the number of inner cuts and gradually removing residual segments in a spiral manner to achieve faster and higher quality cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple perpendicular grid-like inner cuts are used to form shapes, then the cutting operation can be completed, but the processing time increases and edge quality deteriorates due to larger residual workpiece segments
Solution Approach 1:
The cutting path is segmented into two distinct phases: (1) forming intersecting apertures that create smaller residual segments, and (2) a continuous spiral path that gradually removes these segments. This segmentation allows the process to first create favorable conditions for quality (small segments) and then efficiently remove material (continuous motion).
Solution Approach 2:
The intersecting aperture lines are formed as preliminary cuts before the final continuous cutting path. These preliminary cuts create a pattern that divides the workpiece into smaller segments that will be removed by the subsequent spiral path, preparing the workpiece structure to achieve better edge quality during the main cutting operation.
2Manufacturing precision
If multiple perpendicular grid-like inner cuts are formed, then the shape can be defined, but the number of cuts increases reducing processing efficiency
Solution Approach 1:
Instead of defining the shape through multiple perpendicular cuts that create a grid pattern, the invention inverts the approach by using intersecting aperture lines that meet at a central point, creating radial segments. This inverted geometry reduces the number of required cuts while maintaining shape definition accuracy.
Solution Approach 2:
The final cutting path uses a spiral (curved) trajectory instead of straight perpendicular lines. This curved continuous path efficiently defines the shape boundary while reducing the total number of cuts compared to a grid-like perpendicular pattern, combining shape precision with cutting efficiency.
3Productivity
If larger residual workpiece segments remain after inner cuts, then fewer cuts are needed, but the processing quality decreases
Solution Approach 1:
The invention changes the parameter of residual segment size by using intersecting aperture lines that create smaller segments compared to conventional perpendicular grid cuts. This parameter change (smaller segments) directly improves processing quality while the continuous spiral removal path maintains efficiency by avoiding multiple separate cutting operations.
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 enables faster and more efficient cutting with higher quality edges by forming fewer inner cuts, reducing residual workpiece fragments to a size that falls between supporting elements, thus improving processing quality and efficiency.
Implementation Method 1
forming intersecting apertures in a workpiece with a laser beam by moving the laser beam along intersecting line paths
Implementation Method 2
cutting out a portion of a shape from the workpiece by moving the laser beam along a continuous final path extending around an intersection point of the intersecting line paths
Data Source
AI summary
In some aspects, methods includes forming intersecting apertures in a workpiece with a laser beam by moving the laser beam along intersecting line paths, and cutting out a portion of a shape from the workpiece by moving the laser beam along a continuous final path extending around an intersection point of the intersecting line paths.