Laser Nozzle Wedge Cavity Swirling Flow Thick Sheet Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser machining nozzles face challenges in achieving high-quality cuts with low cut edge roughness and efficient feed rates when cutting thick sheets, as increased gas pressures lead to plasma formation, which degrades cut quality, and reducing gas pressure results in burr formation.
Innovation Solution
A laser machining nozzle design featuring a cavity with a wedge-shaped edge at the orifice, creating a swirling flow that enhances gas jet momentum and reduces frictional losses, allowing for high discharge speed and efficient momentum transfer without enlarging the orifice diameter, thus minimizing plasma formation and improving cut edge quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the orifice diameter of the laser machining nozzle is enlarged to process thicker sheets, then the gas pressure needed is reduced, but the gas density in the cutting gap increases leading to increased plasma formation probability
Solution Approach 1:
The invention changes the geometric parameters of the nozzle by introducing a cavity with specific dimensions (depth d1 and diameter d2) behind the orifice. This cavity geometry modifies the gas flow parameters, creating a swirling flow that increases gas discharge speed and momentum without enlarging the orifice diameter, thus maintaining low gas density and reducing plasma formation while enabling thick sheet cutting
Solution Approach 2:
The invention adds a spatial dimension by introducing a cavity behind the orifice opening. This cavity creates a three-dimensional flow structure with swirling motion, transforming the simple linear gas jet into a complex three-dimensional flow pattern that enhances gas utilization and momentum transfer to the cutting front, enabling thick sheet cutting without increasing orifice diameter or gas pressure
2Manufacturing precision
If the gas pressure is reduced to achieve better cut edge qualities, then plasma formation is minimized, but distinct burr formation occurs
Solution Approach 1:
The invention changes the flow parameters by introducing a cavity that generates swirling flow. This swirling flow increases the gas discharge speed and momentum, allowing the gas jet to effectively remove molten material and prevent burr formation even at reduced gas pressures, thus achieving both good cut edge quality and burr-free surfaces
Solution Approach 2:
The invention introduces dynamic swirling flow instead of static linear flow. The cavity geometry creates rotational motion in the gas jet, which dynamically adapts to the cutting process, enhancing the gas jet's ability to penetrate and clear molten material from the cut zone, preventing burr formation while maintaining low gas pressure for high cut edge quality
3Object-affected harmful factors
If the orifice diameter is kept small to avoid plasma formation, then gas pressure must be increased, but this increases gas density and plasma formation probability
Solution Approach 1:
The invention changes the velocity parameter of the gas flow by introducing a cavity that generates swirling flow. This increases the gas discharge speed from the orifice, allowing small orifice diameters to maintain low gas pressure while still achieving sufficient momentum to prevent plasma formation and ensure effective cutting
Solution Approach 2:
The cavity performs preliminary action by pre-swirling the gas flow before it exits the orifice. This pre-conditioning of the gas flow creates a high-momentum jet that is more effective at preventing plasma formation and clearing molten material, allowing the use of smaller orifices at lower pressures
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 nozzle achieves high-quality cuts with low cut edge roughness and increased feed rates by maintaining high-grade quality cuts in thick sheets, reducing plasma formation, and optimizing gas consumption, while avoiding the development of a diffuser that would increase momentum loss.
Implementation Method 1
With the aid of the wedge-shaped edge according to the invention, a swirling flow develops
Implementation Method 2
the main gas jet flows first of all into a volume (dynamic pressure volume), the pressure of which is elevated compared with the surroundings
Implementation Method 3
When the inner sides of the cavity are arranged transversely or run obliquely with respect to the direction of the gas supply chamber, processing gas is able to flow virtually radially into the cavity
Data Source
AI summary
A laser machining nozzle having at least one supply chamber for the laser beam and for a processing gas has a cavity arranged in the region of the orifice of the gas supply chamber, which cavity is open in the direction towards the workpiece to be machined, this opening having a wedge-shaped edge.