Laser Nozzle Outlet Geometry for Faster Thick-Material Cutting
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Solution Overview
Problem
Existing laser cutting technologies face challenges in achieving higher cutting speeds and cutting thicker materials while maintaining the quality of the cut surfaces, especially when using a specific laser power.
Innovation Solution
A method for producing a laser nozzle with a unique outlet design, where the outlet initially has a smaller diameter than the laser beam, allowing the laser to cut away the edge and form an opening precisely adapted to the beam, enhancing gas eddying and material removal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the outlet diameter is made larger to allow higher cutting speeds, then productivity increases, but the quality of the cut surface deteriorates due to increased material oxidation and poor gas flow control
Solution Approach 1:
The outlet is pre-formed with a diameter smaller than the laser beam diameter before actual cutting operations. This preliminary configuration allows the laser beam itself to subsequently enlarge the outlet to the optimal size, ensuring both high cutting speed and quality without manual intervention or complex adjustment mechanisms.
Solution Approach 2:
The outlet diameter is dynamically adjusted through laser ablation from an initial small diameter to a larger operational diameter. This parameter change enables the system to optimize both cutting speed and surface quality by allowing the outlet size to adapt to the specific cutting requirements through controlled material removal.
2Manufacturing precision
If the outlet diameter is made smaller to improve cut quality and gas flow control, then manufacturing precision improves, but productivity decreases due to restricted material removal
Solution Approach 1:
The laser beam serves a dual function: it both cuts the workpiece and simultaneously enlarges the outlet to the optimal diameter. This self-service mechanism eliminates the need for separate outlet formation processes and allows the system to automatically achieve the balance between cut quality and productivity required for each specific application.
3Length of stationary object
If laser power is increased to cut thicker material, then the ability to process thicker material improves, but the quality of the cut deteriorates due to increased oxidation and thermal effects
Solution Approach 1:
The cutting gas acts as an intermediary medium that is optimized through the specifically designed outlet. The outlet geometry, formed by laser ablation, creates ideal gas flow patterns that enhance the flushing of molten material and provide better protection against oxidation, allowing higher laser powers to be used on thicker materials without compromising cut quality.
4Productivity
If cutting gas pressure is increased to improve material removal, then productivity increases, but energy consumption increases and cut quality may deteriorate due to excessive turbulence
Solution Approach 1:
The outlet is designed with locally optimized geometry through laser-formed enlargement, creating specific flow characteristics at the critical outlet region. This local quality optimization ensures efficient gas flow and material removal at moderate pressures, reducing the need for high gas pressures and associated energy consumption while maintaining high productivity.
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
The solution enables higher cutting speeds and the ability to cut thicker materials with improved quality, as the optimized gas flow and precise opening size minimize material oxidation and enhance the removal of vaporized material.
Implementation Method 1
the laser beam is allowed to cut away an edge portion of the outlet to form the opening
Implementation Method 2
cutting gas may be conducted under high pressure through the channel and outlet
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
This document discloses a laser nozzle (1) for gas-assisted cutting by means of a laser beam (6), comprising an inlet (12), an outlet (13), and a channel (14) extending between the inlet (12) and outlet (13) for the laser beam (6) and cutting gas. The channel (14) has a central axis (Z). The channel (14) has a first portion (141) with an inwardly facing surface (112). The laser nozzle comprises a substantially helical blade (16) which extends radially inwardly from the inwardly facing surface (112) and extends over at least 300 degrees around the central axis (Z) and along the inwardly facing surface. The document also discloses an inset for a laser nozzle, a laser cutting device and methods of laser cutting.