Laser-Cut Welding Tab Retention for Clean Part Separation
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Solution Overview
Problem
In laser cutting methods, the separation of processed parts from workpieces often results in fine protrusions due to micro joints or melted residues, requiring additional steps for removal, and there is a risk of the processed part being caught in pin supports or adhering to the workpiece, hindering laser processing head movement.
Innovation Solution
A laser cutting method that forms a welding protruding-tab on the scrap material, allowing the processed part to be securely retained without micro joints, by creating a cantilever-shaped tab that is welded to the processed part, ensuring stable retention and easy separation with minimal residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If micro joint processing is used to prevent processed part separation, then the processed part is retained on the workpiece, but fine protrusions occur on the processed part requiring additional removal steps
Solution Approach 1:
The invention divides the retention mechanism into two distinct functional components: a retention protrusion that provides mechanical retention and a separate welding area that provides bonding force. This segmentation allows each component to perform its specific function optimally without interfering with the other, preventing fine protrusions on the processed part while ensuring reliable retention.
Solution Approach 2:
The retention protrusion acts as an intermediary element between the processed part and the workpiece. Instead of directly joining the processed part to the workpiece (which causes fine protrusions), the retention protrusion serves as a mediator that can be welded to the workpiece while providing a clean separation interface with the processed part.
2Productivity
If fiber laser is used for cutting, then the focused beam diameter is smaller and cut slit is narrower, but the processed part is more likely to be caught in the workpiece hindering laser processing head movement
Solution Approach 1:
The invention extracts the retention function from the main cutting operation by creating a separate retention protrusion structure. This allows the narrow cut slit from fiber laser cutting to be used effectively while the retention protrusion prevents the processed part from being caught, separating the cutting precision function from the retention function.
3Reliability
If adhesive is supplied onto the cut line to prevent separation, then the processed part is retained on the workpiece, but the adhesive must be removed when separating the cut piece
Solution Approach 1:
The retention protrusion is designed as a temporary structure that serves its retention purpose during laser cutting and is then easily removed or left as part of the workpiece. Unlike adhesive that requires cleaning or removal steps, the retention protrusion provides a simple mechanical solution that does not contaminate the processed part.
4Reliability
If melted residue is used to adhere the processed part to the workpiece, then the processed part is retained, but the melted residue may firmly adhere to the product requiring removal
Solution Approach 1:
The invention applies local quality by creating a retention protrusion with a specific geometry that concentrates the welding action in a localized area (the welding area at the base of the protrusion) while leaving the rest of the processed part surface unaffected. This ensures retention at the joint location without contaminating the processed part surface with melted residue.
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 method effectively retains the processed part without leaving significant traces and prevents it from falling, allowing for reliable and long-term stability, with controlled retention forces through adjustable tab dimensions and escape distances, enhancing processing efficiency.
Implementation Method 1
By performing laser-cutting along an outline of the processed part after forming the cut slit, a welding protruding-tab in a cantilever shape is formed
Implementation Method 2
further melting an edge of a cut slit that is cut, by laser and causing the melted residue to adhere to the workpiece
Implementation Method 3
welding the free end of the welding protruding-tab and the peripheral surface of the processed part
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
In a laser cutting method, a cut slit (7) of a welding protruding-tab (11) configured to be bent by laser cutting along an outline (9L) of a processed part (3) and press a peripheral surface of the processed part (3) is laser-cut in advance in a periphery of the processed part (3) that is cut from a workpiece (1), and an outline slit (9) is formed by performing laser cutting along the outline (9L) of the processed part (3) and a free end of the welding protruding-tab (11) is welded to the peripheral surface of the processed part (3). According to the above described laser cutting method, it is possible to retain the processed part (3) reliably and stably for a long period, and it is possible to easily separate the processed part (3) from the workpiece (1) with almost no trace left on the processed part (3).