Overcome the difficulties of laser cutting machine cutting metal pipe technology

Overcome the difficulties of laser cutting machine cutting metal pipe technology 

Accompanied by the rapid growth of the stainless steel pipe production and consumption, laser cutting tube equipment are growing rapidly in popularity, the demand of personnel and technology of laser cutting machine grown quickly.This highlights the shortage and lag in the laser cutting equipment and laser cutting Overcome the difficulties of laser cutting machine cutting metal pipe technology 

Accompanied by the rapid growth of the stainless steel pipe production and consumption, laser cutting tube equipment are growing rapidly in popularity, the demand of personnel and technology of laser cutting machine grown quickly.This highlights the shortage and lag in the laser cutting equipment and laser pipe cutting talent and technology, which is also reflected in some stainless steel enterprises, with advanced laser cutting equipment, but still exposed pipe cutting efficiency is low, poor quality management, resulting in the phenomenon of serious waste of pipe. 

Laser pipe cutting processing technology is a high production efficiency, productivity and strong technology.Can modified the design at the last minute without affecting the entire the production process.Greater benefits is that the end user can control the short version or medium version in production without making a large number of templates, so you can give more quickly respond to customer needs, so this does not need to make the molds.From the perspective of flexibility, laser cutting processing technology can be used to process any shape of the processing program, and the laser can be completed in any direction. The shape of the template can be changed quickly, without the help of any tool, providing the possibility to process a competitive personalized packaging or trademark. Accuracy is one of the advantages of digital systems. Laser processing can offset printing and finishing process in the presence of inaccurate, such as material may produce flexible deformation, the laser can be based on these deformation is adjusted, and the traditional template making is not. Laser tube cutting products processing is a very accurate and high level technology, Of course, this requires a certain cost of investment in the early stage, the following will focus on the relevant issues related to laser cutting and provide targeted solutions.  
Worker can draw,nesting,cutting with the professional pipe cutting and nesting software,generate cutting program,then full automatic laser cutting for the large length of stainless steel pipe.The speciality of tube nesting software is the basis and prerequisite for the realization of high volume, high efficiency and high quality cutting production of laser tube cutting machine. 
At present, the laser pipe cutting process, there are some quality problems, for example: led to cut some parts over burning, pipe cutting inclined plane for burning, part corner, and cutting circular parts circle deformation or cannot be closed, pipe directly lead to serious waste and cut tube production efficiency is low. CNC pipe cutting technology refers to the NC system of the cutting control software to provide advanced cutting tube technology and rich pipe cutting experience, pipe cutting workers to operate by skilled in the use of control system, to achieve high quality, high efficiency of CNC cutting. CNC laser cutting technology is a high volume, high efficiency, high quality cutting production methods, CNC cutting pipe is the core of CNC cutting system. 
Pipe cutting process due to pipe cutting (especially for tubular diameter of square tubes), slag, attached on the tube wall, most of the heat produced in the cutting is absorption of the workpiece, cutting density is large, often cause overheating pipes, corner and square tube four horns, burning, seriously affecting the ring incision quality, can't even cutting. For such problems, the following solutions can be used: 
1, increase oxygen pressure.           
2, improve the angular speed of synthesis by software.           
3, laser cutting headband height sensing with dynamic system can guarantee in the process of cutting, cutting the nozzle and the workpiece plane height remained unchanged (focus unchanged), cutting effect does not change with the surface of the workpiece affected. 
The proposed solution will improve the laser tube cutting processing equipment efficiency in the use of, so as to improve the cutting efficiency is low, poor quality management, pipe caused serious waste, improve production and processing enterprises product efficiency, for the enterprise to create a better profit. talent and technology, which is also reflected in some stainless steel enterprises, with advanced laser cutting equipment, but still exposed pipe cutting efficiency is low, poor quality management, resulting in the phenomenon of serious waste of pipe. 
Laser pipe cutting processing technology is a high production efficiency, productivity and strong technology.Can modified the design at the last minute without affecting the entire the production process.Greater benefits is that the end user can control the short version or medium version in production without making a large number of templates, so you can give more quickly respond to customer needs, so this does not need to make the molds.From the perspective of flexibility, laser cutting processing technology can be used to process any shape of the processing program, and the laser can be completed in any direction. The shape of the template can be changed quickly, without the help of any tool, providing the possibility to process a competitive personalized packaging or trademark. Accuracy is one of the advantages of digital systems. Laser processing can offset printing and finishing process in the presence of inaccurate, such as material may produce flexible deformation, the laser can be based on these deformation is adjusted, and the traditional template making is not. Laser tube cutting products processing is a very accurate and high level technology, Of course, this requires a certain cost of investment in the early stage, the following will focus on the relevant issues related to laser cutting and provide targeted solutions.  
Worker can draw,nesting,cutting with the professional pipe cutting and nesting software,generate cutting program,then full automatic laser cutting for the large length of stainless steel pipe.The speciality of tube nesting software is the basis and prerequisite for the realization of high volume, high efficiency and high quality cutting production of laser tube cutting machine. 
At present, the laser pipe cutting process, there are some quality problems, for example: led to cut some parts over burning, pipe cutting inclined plane for burning, part corner, and cutting circular parts circle deformation or cannot be closed, pipe directly lead to serious waste and cut tube production efficiency is low. CNC pipe cutting technology refers to the NC system of the cutting control software to provide advanced cutting tube technology and rich pipe cutting experience, pipe cutting workers to operate by skilled in the use of control system, to achieve high quality, high efficiency of CNC cutting. CNC laser cutting technology is a high volume, high efficiency, high quality cutting production methods, CNC cutting pipe is the core of CNC cutting system. 
Pipe cutting process due to pipe cutting (especially for tubular diameter of square tubes), slag, attached on the tube wall, most of the heat produced in the cutting is absorption of the workpiece, cutting density is large, often cause overheating pipes, corner and square tube four horns, burning, seriously affecting the ring incision quality, can't even cutting. For such problems, the following solutions can be used: 
1, increase oxygen pressure.           
2, improve the angular speed of synthesis by software.           
3, laser cutting headband height sensing with dynamic system can guarantee in the process of cutting, cutting the nozzle and the workpiece plane height remained unchanged (focus unchanged), cutting effect does not change with the surface of the workpiece affected. 
The proposed solution will improve the laser tube cutting processing equipment efficiency in the use of, so as to improve the cutting efficiency is low, poor quality management, pipe caused serious waste, improve production and processing enterprises product efficiency, for the enterprise to create a better profit.

Laser cutting machine cutting 7 types different metal materials

Laser cutting machine cutting 7 types different metal materials

Metal on the initiation of 10.6 um laser beam absorption rate is only from 0.5% ~ 10%, however, when with a power density of more than 106w/cm2 focused laser beam irradiation to the metal surface, but it can in the microsecond time soon so that the surface begins to melt. The absorption rate of most metals in the molten state has risen sharply, which is generally improved by 60%~80%.

1.Titanium and its alloys.          

Pure titanium can be very good coupling focused laser beam transformation of heat energy, auxiliary gas oxygen chemical reaction, cutting speed, but easy to generate oxide layer on the cut edge, not careful will cause too much. For the sake of safety, the use of air as an auxiliary gas is better, to ensure the quality of cutting.          
Aircraft manufacturing industry commonly used titanium alloy laser cutting quality is better, although there will be a little sticky residue at the bottom, but it is easy to clean up.

2.Nickel alloy.          

Nickel based alloy, also known as super alloy, a lot of variety. Most of them can be carried out to melt and cut.

3.Carbon steel.          

Modern laser cutting machine can cut carbon steel plate with the maximum thickness of up to 20MM, the use of oxidation and melting cutting mechanism to cut carbon steel cutting seam can be controlled in a wide range of satisfaction, the thin sheet of its cut can be narrow to about 0.1MM.

4.Stainless steel.          

Laser cutting is an effective tool for the manufacture of the stainless steel sheet as the main component. In the strict control of the laser cutting process of the heat input measures can be restricted to the edge of the heat affected zone is very small, so that it is very effective to maintain the good corrosion resistance of such materials.

5.Alloy steel.         

The majority of alloy structural steel and alloy tool steel using laser cutting method to obtain good cutting quality. Even some of the high strength materials, as long as the process parameters are properly controlled, can get straight, non stick slag cutting edge. However, for high speed tool steel and hot die steel, laser cutting machine will have the phenomenon of corrosion and slag.

6.Aluminium and alloys.          

Aluminum cutting is a melting laser cutting mechanism, which is mainly used to blow away the molten product from the cutting area. For some aluminum alloys, it should be noted that the prevention of micro cracks on the surface of the cutting seam is noticed.

7.Copper and alloys.         

Copper (copper) because the reflectivity is too high, basically can not use CO2 laser beam cutting. Brass (Red copper) using a higher laser power, auxiliary gas using air or oxygen, can be a thin sheet of cutting.

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Common failures and Solutions of CNC Router

Common failures and Solutions of CNC Router

Any machine can not be preserved intact for a long time,so we should learn to  

judge the common faults and know how to solve them.Here we share some common failures and solutions of cnc router, and we mainly have the following 15:

Ⅰ, the spindle automatically turn or can not stop

1, control card failure;

2, inverter fault

II, when opening the software, the computer prompts "open the card failed,

please check the card" prompt

1, check the driver card is not installed, or to change a PCI card slot;

2, the two data connection line to re install, check there is no phenomenon of 

broken needles;

3, the board has a problem, replace the board.

Ⅲ,Open the software when prompted: three axis alarm, initialization error four

1, check the computer and the machine two data lines have not received;

2, check the control box of the switch board of the fuse is burned, for the 

fuse;

3, check the 85V power supply is normal

Ⅳ,CNC Router appear dislocation or wrong size

1, check the path of the software is correct or not;

2, check the gap size of the screw rod and the rod of the fastening screws are 

not loose;

3, check the software parameter settings correct or not.

Ⅴ,When X axis working,the Z axis can not lift,give it the command go up,but it 

go down.

1, check whether the Z axis motor run well,also check it's power and the drive 

current.

2, check whether the Z axis motor line has bad contact or middle of the case.

Ⅵ,the spindle motor does not turn or reverse

1, check the setting parameters of the inverter;

2, the frequency of the signal line is connected to the inverter.

Ⅶ,Smashing knife phenomenon

1, Z axis motor power is not enough, the coupling loose;

2, Z axis drive current is too small, or signal line is wrong.

Ⅷ,When the software is turned on, the shaft is closed.

1, the problem of the driver or the computer output signal line contact is bad;

2, the motor line contact is bad.

Ⅸ,In the process of engraving, there is a limit phenomenon.

1, check the engraving path is beyond the scope of sculpture;

2, the soft limit of the parameters in the software settings.

Ⅹ,When turn on the machine, it doesn't work.

1, check the start button line is connected and the button is burnt out;

2, check whether the AC contactor short-circuit or burn out.

Ⅺ,Axis running only to one direction

1, check whether the normal work and the coupling line contact line is good;

2, check the motor line for a weld.

Ⅻ,Files cannot be opened normally, and the carved objects appear to be 

deformed.

1, re install the new system and software;

2, check the X, Y axis screw 

XIII,CNC Router's spindle motor suddenly stop or slow down in the process of 

work

1, the operating voltage is not stable or super load, plus a voltage regulator 

can be;

2, check the middle line is connected, whether there is a connecting thread.and screw is loose;

3, carving tools have problems.

XIV,When setting the origin of the engraving machine, sometimes forward, the 

right offset distance

1, limit switch failure, the system back to the system in the process of the 

origin of the limit switch has been closed and open. Change limit switch;

2, drive line loose. Try to fix it.

XV,CNC Router start reset, X axis, Y axis, Z axis position is uncertain

1, limit switch is bad (the limit switch is always closed), can change;

2, the drive line is bad (X axis 14 pin and 15 pin short circuit, Y axis 13 pin 

and 15 pin short circuit, Z axis 31 pin and 15 pin short circuit), change the 

drive line or short circuit can open;

3, the driver board is bad, change the drive board can.

Effect of laser output power on laser cutting

Effect of laser output power on laser cutting 
When using laser cutting machine,the laser output power is a parameter that has a direct relation with the melting ability of the processed. For getting good effect of cutting,we need increase the output power in order to improve the processing ability.

Improve processing capacity:
1, improve the laser cutting speed.          
2, increase the thickness of the processing plate.          
3, processing of aluminum, copper and other high reflection spectral reflectance factor.          
4, zoom lens from the short focal length lens.          
5, the focus of the location from the surface of the processed material changes.

We can determine whether the use of the processing conditions of the output energy is appropriate, according to the processing of the cutting surface and machining in the case of the spark. When the output power is much larger than the standard value, the thermal effect of the incision increases, and the melting loss occurs at the corner. And cut the noodles to become thick, from the upper to the lower part of the vertical.
If the output power value is far less than the standard value, the lower part of the cut is significantly thicker, become the state of digging into. And with the increase of the amount of adhesion of slag, it is difficult to remove. Mars is lagging in the cutting process in the opposite direction in the cutting process.
Suitable for the processing of the output conditions exist within a certain range, the thinner the thickness of the processing board, the wider the range of output conditions. Output processing in proper conditions, the cutting surface streak fine, lower relative to the speed of light slow.

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Notes when using the CO2 laser tube

Notes when using the CO2 laser tube

Ⅰ.Firstly,pls connnect the cooling water,following the principles of low position water in,high position water out.Make sure that the cooling water is full in cooling pipe,and no be with any bubble.Then power on laser machine.

Requirements: cooling water use soft water (distilled water or pure water), and should always pay attention to the temperature of the cooling water, the water temperature should be control in 25 to 30 DEG C, not too high or too low, especially in the summer, once found the water temperature is too high should be timely replacement of water cooling or stop to rest for a period of time: cold area cooling water shall not be frozen, especially after the shutdown of laser, not let cooling water storage in the laser tube, in order to avoid cooling water ice lead to burst. (special attention: the use of alternating current users, cooling water tank must be grounded);

Ⅱ.Two surpporting points are in the 1/4 of the total length of laser tube,pls make sure that the flow of cooling water is 2-4L/min.Otherwise, the effect is not good, will cause the jump mode, light spot changes several points lead to power down. Cooling water return port in the tank must be covered with water, or the laser tube cooling water filling in the laser tube at each turn.

Ⅲ.Pay attention to the protection of the laser output window, avoid the work process (including the adjustment of light path in the process)produce smoke sputtering to the output window surface, prevent the output window, surface contamination, the power will drop, then use absorbent cotton or silk cloth dipped in anhydrous alcohol, gently wipe the outer surface of the output window.

Ⅳ.In the process of debugging, adjusting the position of the laser or the rotation of the laser to achieve the best output effect, and then the laser is fixed.

Ⅴ.Please note: avoid high voltage electrode near the accumulation of dust, to keep dry high voltage side as possible from the metal away, to prevent the high voltage spark discharge.

Ⅵ.Pls keep the laser tube clear,no scale in tube when using laser machine,so as to avoid cooling water blocking,poor cooling.Once found scale in tube,pls clean tube with 20% dilute hydrochloric acid.

Ⅶ.The laser tube is a glass product. When installing and using, avoid local stress.

Ⅷ.Please use the laser tube reasonably, save the laser energy, and the working current of the laser tube should not exceed 26mA.

Common problems and treatment methods in laser cutting

Common problems and treatment methods in laser cutting

1.Any kind of thermal cutting technology, in addition to a small number of cases can be from the edge of the board, the general must wear a small hole in the board. Before the laser punching compound machine with a hole punch out first, and then again from the hole at the beginning of laser cutting. Basic method for two kinds of perforation of laser cutting machine without punching device:

Blasting perforation
After the material is irradiated by a continuous laser, a concave hole is formed in the center, and the oxygen flow from the laser beam is quickly removed to form a hole. And sheet thickness is related to the size of the hole and blasting perforation average diameter is half of the plate thickness, so for thick plate blasting perforation diameter larger diameter, should not require higher in precision machining parts, can only be used for waste. In addition, due to the use of oxygen pressure and cutting the same, the splash is larger.

Pulse perforation
Pulsed laser with high peak value is used for melting or vaporization of a small amount of material, air or nitrogen is used as an auxiliary gas to reduce the expansion of the pores due to heat release and the gas pressure is less than the oxygen pressure during the cutting process.
Each pulse laser produced only a small particle injection, and gradually deepened, so thick plate perforation time takes a few seconds. Once the perforation is completed, the auxiliary gas is changed to oxygen for cutting. The perforation diameter is smaller and the perforation quality is better than that of the blasting hole. The laser used in this system should not only have high output power, but also more important is the time and spatial characteristics of the beam, so the general cross flow CO2 laser can not meet the requirements of laser cutting. In addition, a more reliable pneumatic control system is needed in order to realize the gas type, gas pressure switch and perforation time control.In the case of using pulse perforation, in order to obtain high quality cut, from the workpiece at rest, the pulse perforation to the workpiece constant velocity continuous cutting transition technology should be paid attention to. Theoretically, it is usually possible to change the cutting conditions of the accelerating section, such as the focal length, the position of the nozzle and the gas pressure, but in fact, the possibility of the above conditions is not very much due to the time is too short. In the process of industrial production, the method of changing the average power of laser is used to compare the reality, the specific method is to change the pulse width, change the pulse frequency, and change the pulse width and frequency.

2. cutting holes (diameter and thickness) analysis of deformation
This is because the machine (only for high power laser cutting machine) in machining holes not take the blasting perforation, but with pulse perforation (soft puncture), which makes the laser energy in a very small area is too concentrated, non machining area was burned, cause deformation of the hole, the processing quality is affected. Then we should be in the process, pulse perforation (soft puncture) to blasting perforation (ordinary puncture) way to solve. For small power laser cutting machine is just the opposite, in machining should adopt way pulse perforation to achieve better surface finish.

3.when the laser cutting of low carbon steel, the solution to the work of burr
According to the working principle and design of CO2 laser cutting, and analysis the following reason is caused by machining burrs in the main reason: the laser focus on the position is not correct, need to be adjusted according to the focus position test, offset focus; the laser output power is not enough, need to check the laser generator is normal or not, if the normal, is to observe the effect of laser numerical control output button is correct, adjust the line; the cutting speed is too slow, the need to increase the line speed in operation control; the purity of cutting gas is not enough, need to provide high quality gas cutting work; laser focal shift, need to be adjusted according to the focus position test, offset the focus of the machine running time is too long; the stability, the need to shutdown and restart.

4.Laser cutting of stainless steel and aluminum plated zinc plate, analysis of the causes of burr formation.
The factors above, first consider the low carbon steel cutting burr, but not simply accelerate cutting speed, because increased speed sometimes sheet cutting not to wear, this kind of situation in processing aluminized zinc plate is particularly prominent. At this time should be integrated into other factors to consider the machine to solve, such as whether the nozzle to replace, rail movement is not stable, etc..

5.Analysis of laser machine can not cut through
Analysis revealed that several of the following is instable processing of: laser head nozzle selection and processing board does not match the thickness; laser cutting line speed is too fast, need to operate the control lines are reduced speed; in addition, also need to pay special attention to, in the laser cutting machine cutting more than 5mm carbon steel needs to be replaced laser lens focal length of 7.5 ".

6.Method for solving non normal spark in cutting low carbon steel
This situation will affect the cutting section of the parts finish machining quality. At this time, in the case of other parameters are normal, should consider the following: laser head nozzle loss, should be promptly replace the nozzle. In the case of no new nozzle replacement, the cutting work gas pressure should be increased; the nozzle and the laser head are connected at the screw thread. At this point should be immediately suspended cutting, check the laser head connection status, re good thread.

7.Selection of puncture point in laser cutting
Laser cutting the working principle of the laser beam is: in the process, material after the irradiation of laser in the center of the formation a pit, and then by the work flow and laser beam coaxial soon will be molten material removal of the formation of a hole. This hole is similar to line cutting of the thread hole, laser beam on this hole for the processing of opening and starting point of contour cutting, usually under flight light path laser beam walk line direction and the parts to be machined vertically cutting contour tangent direction. Therefore, laser beam in began to penetrate the plate into the cutting contour parts of this period of time, the cutting speed in vector direction will have a great change, namely the direction vector of 90 degrees rotation by vertical to the cutting contour tangent direction turn and cutting contour tangent coincidence, and contour tangent angle is 0 degrees. In this way, the cutting surface of the processed material is relatively rough cut surface, which is mainly in the short time, the laser beam in the direction of the movement of the vector is very fast. Therefore, in the use of laser cutting parts, we should pay attention to this aspect of the situation. , in the design of components of surface cutting fracture no roughness can not to do manual processing in laser cutting programming, to control the software automatically generates the puncture point; however, when design of machining cutting section has higher roughness requirements, note to this problem, usually in series laser cutting program of laser beam starting position be manually adjusted, namely artificial for the puncture point of control. The need to produce the original laser puncture point program moved to the reasonable position of need, to reach the surface precision requirements of the processing parts.

The differences of Fiber laser,YAG laser,CO2 laser and disk laser

The differences of Fiber laser,YAG laser,CO2 laser and disk laser

CO2 laser is also known as carbon dioxide laser, it is composed of CO2 gas and nitrogen, hydrogen and other gases, to 10.6nm laser wavelength for the laser beam to produce more than 20 kW of power, can realize the continuity of the work, is often used in laser marking machine, laser cutting machine, and should be used quite widely. Because of its gas pipe composition, so should pay attention to the use of a lot of problems, in order to avoid adverse consequences, the following is a brief analysis of the matter and CO2 laser and other lasers.The difference between CO2 laser and other lasers

Photoelectric conversion rate:

Fiber laser reached 30%,YAG solid state laser is only 3%,CO2 laser 10%,Laser disc reached 15%.

Maximum output power:

Fiber laser reached 50kW,YAG solid state laser 6kW,CO2 laser reached 20kW,The disc laser reached 8kW.

BPP (4/5kw) aspects:

Fiber laser is less than 2.5,YAG solid state laser is about 25,CO2 laser reached 6,The laser disc is about 8.

Semiconductor pump life:

Fiber laser can work continuously for more than 10 million hours, YAG laser can be about 1000h, CO2 laser is expected at about 5 000 h, disk laser life about 1 million hours.

Maintenance and operation cost / hour (4/5KW):

Fiber laser per hour 2 yuan, YAG solid laser 35 yuan per hour, CO2 laser per hour 20 yuan, disk laser per hour 8 yuan.

Maintenance aspect:

Fiber laser no need maintenance,YAG laser and laser discs need regular maintenance,CO2 laser needs to be maintained.

Flexible machining aspect:

Fiber laser is very suitable,YAG laser and laser disc,CO2 laser is not suitable for flexible machining.

Stability aspect:

Optimum stability of fiber laser,CO2 laser and laser disc stability,The stability of YAG solid state laser is not very good.

Absorption% - Steel

Fiber laser, YAG laser, laser disc is about 35, CO2 laser is about 12.

Aluminum absorption%

Fiber laser, YAG laser, laser disc is about 7, CO2 laser is about 2;

Parts to be replaced:

Fiber laser has a high brightness broadband single core junction semiconductor laser, pumping time of more than 200 thousand H. A semiconductor is damaged, replace only $300~500, because each semiconductor pump source is independent of each other;YAG laser is pumped;CO2 laser is to add gas;The disc is mainly laser pumping source needs to be replaced frequently, each change between $20~23 million.