Laser Cutting of Plate-and-Flange Steel for Free-Falling Cutouts
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Solution Overview
Problem
Laser processing of steel materials is inefficient due to warp deformation caused by heating and cooling, leading to cutout pieces being held by the flange instead of freely falling, which reduces working efficiency, especially with fiber lasers that have higher heat input efficiency and narrower cut widths.
Innovation Solution
A laser processing method and device that sets a cutting line across a first and second plate-shaped part of a workpiece, forming notches in the second part to divide the cutout piece into a tip end and base portion, and cutting the first part along the cutting line with the laser beam from one direction, using a processing head and controller to control the emission and movement of the laser beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a laser beam is used to cut steel materials, then cutting speed and precision are improved, but warp deformation occurs due to heating and cooling causing cutout pieces to be held by the flange instead of freely falling
Solution Approach 1:
The patent applies preliminary action by forming notches in the flange before performing the main cutting operation. These notches create gaps that allow cutout pieces to separate freely from the workpiece, preventing them from being held by the flange due to warp deformation. The notches are created in advance to anticipate and prevent the separation problem that would otherwise occur during cutting.
2Use of energy by moving object
If fiber laser is used for cutting, then heat input efficiency is improved and cut width is narrowed, but warp deformation increases causing cutout pieces to be held by the flange
Solution Approach 1:
The patent applies segmentation by dividing the flange structure through notches, creating separate regions that can move independently. This segmentation allows the flange to accommodate warp deformation without preventing cutout piece separation. The notches divide the continuous flange structure into segments that can flex and deform without holding the cutout pieces.
Solution Approach 2:
The patent converts the harmful effect of warp deformation into a beneficial outcome by designing notches that utilize the deformation to facilitate cutout piece separation. Instead of trying to prevent warp deformation, the design accepts it and structures the notches so that even when the flange deforms, the cutout pieces can still fall freely through the notch openings.
3Ease of operation
If manual operation is performed to separate cutout pieces held by the flange, then complete separation is achieved, but working efficiency is reduced
Solution Approach 1:
The patent applies self-service by designing the notching system to automatically enable cutout piece separation without requiring manual intervention. The notches are positioned and sized so that gravity and the cutting process itself are sufficient to cause cutout pieces to fall freely, making the system self-sufficient for separation and eliminating the need for additional manual 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 minimizes the reduction in working efficiency during laser processing of steel materials by ensuring cutout pieces fall freely, maintaining continuous cutting of the web, even when notch tip end pieces are held by the flange, thereby enhancing processing efficiency.
Implementation Method 1
a portion with cross hatching that corresponds to the back edge portion 622c close to the cutting line Ls43, at an inner surface C13a side of the web C13 is heated by the laser beam LsA to increase in temperature and thereafter, naturally decreases in temperature.
Implementation Method 2
Due to the temperature increase and decrease, the web C13 tries to perform warp deformation that makes the inner surface C13a on a heated side concave.
Implementation Method 3
When a material to be processed such as a shape steel and a steel pipe is cut with a laser beam
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A workpiece (W) having a first plate-shaped part (1) and a second plate-shaped part (2) connected to the first plate-shaped part (1) in a direction to cross the first plate-shaped part (1) is cut with a laser beam. A cutting line (Lc1) across the first plate-shaped part (1) and the second plate-shaped part (2) is set. In the second plate-shaped part (2), a notch portion (2a) that opens to a tip end portion (2b) of the second plate-shaped part (2) and is along the cutting line (Lc1) is formed by cutting with the laser beam so that a cutout piece (2ah) that is cut out by forming the notch portion (2a) is divided into a tip end portion and a base portion. The first plate-shaped part (1) is cut along the cutting line (Ls1) by irradiation with the laser beam from one direction.