Laser Piercing Beam Offset for Molten Metal Scatter Control
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Solution Overview
Problem
During laser processing of sheet metal, the scattering direction of molten metal is random, leading to adherence of molten metal to the product, which reduces yield and increases the likelihood of processing defects.
Innovation Solution
A processing program creation device and method that calculate an optimum scattering angle to control the direction of molten metal scattering during piercing processing, ensuring the molten metal is scattered away from the product and does not interfere with processing paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piercing processing is performed with the laser beam at the center of the nozzle opening, then the processing is simple and stable, but the molten metal scatters randomly and adheres to the product, reducing yield and causing defects
Solution Approach 1:
The patent applies asymmetry by intentionally displacing the laser beam from the center of the nozzle opening to a specific off-center position. This asymmetric positioning creates a controlled scattering direction that directs molten metal away from the product, thereby preventing adhesion and improving yield while maintaining processing stability
Solution Approach 2:
The patent changes the parameter of laser beam position from the conventional center position to a calculated off-center position. This parameter change is determined by the optimum scattering angle calculation, which considers the distance between the nozzle and sheet metal, allowing the system to optimize molten metal scattering direction and prevent defects
2Reliability
If a sufficient space is provided for forming the pierced hole away from the product, then molten metal adhesion is prevented, but the maximum number of products that can be cut out cannot be increased, reducing productivity
Solution Approach 1:
By using asymmetric laser beam positioning, the patent enables pierced holes to be formed closer to the product boundaries without risking molten metal adhesion. This reduces the required spacing between products and increases the number of products that can be cut from a single sheet
Solution Approach 2:
The patent changes the spatial parameter by reducing the distance between the pierced hole position and the product, made possible by the controlled scattering mechanism. This parameter optimization allows tighter product arrangement and higher productivity
3Adaptability or versatility
If the sheet metal has a great thickness, then the piercing processing can handle thicker materials, but the formation of the pierced hole takes a long time and molten metal distribution becomes non-uniform, causing random scattering
Solution Approach 1:
The patent applies parameter changes by adjusting the laser beam position based on the sheet metal thickness. For thicker materials, the optimum scattering angle calculation accounts for the increased processing time and heat accumulation, determining a beam displacement that ensures uniform molten metal distribution and controlled scattering direction throughout the piercing process
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 increases yield by allowing for closer placement of products and reduces processing defects by effectively managing the scattering of molten metal, thereby improving the efficiency of laser processing.
Implementation Method 1
a laser beam that is emitted from a laser oscillator
Implementation Method 2
molten metal generated by the laser beam
Implementation Method 3
blowing assist gas according to the material of the sheet metal onto the sheet metal
Data Source
AI summary
An optimum scattering angle calculator calculates an optimum scattering angle at which molten metal is most desirably scattered at a time of piercing processing of opening a pierced hole in a sheet metal to fabricate a first product, the molten metal being not adhered to an approach path and not adhered to a processing path for a second product positioned within a search region centered on a center of the pierced hole at the optimum scattering angle. A program creator creates a processing program by adding an auxiliary code to a code for fabricating the first product, the auxiliary code indicating that, at a time of the piercing processing on the first product, a position of a laser beam in an opening of a nozzle is displaced in an angle direction of the optimum scattering angle from a center of the opening, the laser beam being emitted from the opening.