One of the most important applications of fiber lasers is laser cutting. Fiber laser cutting is used in almost every modern industry due to the several benefits it provides.
Cylion are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.
Therefore, having an understanding of 'what is fiber laser cutting' and how it works may provide you with a new alternative technology for your particular industrial applications.
The good thing is that learning and using fiber laser technology is a lot simpler than alternative methods. This article will explore the in-depth working process of fibre laser cutting and its associated parameters. You will also learn about the various types of laser cutting operations, their benefits, limitations, and their different applications.
What is Fiber Laser Cutting?
Fiber laser cutting is a type of industrial laser cutting technology that uses the heat of a fiber laser for melting and removing the workpiece material, causing a clean cut. Laser stands for Light Amplification by Stimulated Emission of Radiation.
Fiber laser technology uses a very narrow light beam on the target material. The light is focused by a moving system of optics in the laser machine.
There are many different types of laser generation methods. Fiber lasers are named so because they use an optical fiber as the active gain medium for light amplification.
The optical fiber medium is doped with rare earth elements such as neodymium, ytterbium, thulium, erbium, etc.
The fiber laser was invented in by Elias Snitzer. He demonstrated this laser later in . The evolution of lasers for cutting applications occurred in by Western Electric Engineering Research Center. These laser cutting machines were used to drill holes in diamonds.
The British further evolved the process in into laser-assisted oxygen jet cutting. Within a decade, laser cutting machines became common for cutting even the hardest materials, such as titanium, in aerospace applications.
What are the Main Components of a Fiber Laser Cutting System?
The main parts and components of a fiber laser cutting machine are:
Fiber lasers use a fiber doped fiber optic cable as the laser source. There are many different types of rare earth materials available for doping. This leads to multiple options for fiber laser source. Ytterbium-doped fiber lasers are among the most common types of laser source among fiber lasers. Different doping materials produce laser of different wavelength.
The cutting head is the part that outputs the laser from the system and focuses it on the workpiece. It c a focus consists of a lens, a nozzle, and a focus tracking system. This is a movable part of the fiber laser cutting machine. The movement is according to the direction of the cut. The height of the cutting head from the workpiece is also adjustable.
Servo motor is the part responsible for the movement of the optics and mechanical parts of the laser cutting machine. Modern laser cutting machines have precise servo motors capable of minute movements of the optical components. The speed of the servo motor is also highly controlled. The precision of the laser cutting is largely dependent on the movement of the servo motor.
Laser machine parts generate a high amount of heat. Therefore, it requires a cooling system to ensure the internal components are not damaged. This job is done by the water chillers. Water chillers can drop the temperature of the entire fiber laser cutter very quickly.
The worktable is the area for mounting the workpiece. The worktable, bed, and beam are collectively called the host. The host contains various servomotors for the relative movement in the z-axis.
One of the benefits of a fiber laser cutting machine is its ability to be automated through a CNC control system. The CNC controller interprets the program instructions and passes it along to the various parts of the machine. The CNC controller moves the cutting head in the X, Y, and Z axis accordingly.
The assist gas system is used to blow away the molten material from the workpiece. The laser beam is only capable of melting the workpiece material. Without the assist gas system, the molten material will cool-off and welding will take place. The assist gas system puts pressure on the molten material and pushes it away. The gas used may be oxygen, nitrogen, or air.
Control panel is the interface where the operator can interact with the machine and adjust various settings. The control panel also has features like the emergency stop button. There is generally a display to preview the settings and learn about any error codes and messages.
How Does Laser Cutting Work?
Here is a step by step breakdown of the working process of laser cutting systems:
The laser cutting process starts with the generation of the laser beam. There is a separate laser generation system for this purpose. Laser generation is a multi-stage process that starts with the creation of light in the laser diodes. This initial light is also known as the pump light.
Fiber optic cable systems transfer the pump light beam to other parts of the machine. The fiber optic system consists of a fiber core and a cladding. The cladding is wrapped around the core and acts as a type of mirror for the total internal reflection of the laser beam. An optics cable also ensures that no light beams escape the core, leading to complete efficiency.
Light amplification occurs in a special chamber of the fiber optic cable. This chamber is doped with rare earth materials like Ytterbium. When the light rays interact with the doped particles, the electrons of the particles get excited to a higher energy state. When these electrons fall back to their native state, they release energy in the form of light. Continuous excitation and relaxation of the photons create a light of high intensity. This is how an amplified laser beam is produced. A system of mirrors in the laser cavity are used to guide this light in the right direction.
This is also where the differences in the wavelength of different materials come into effect. Different materials have different excitation and relaxation states of the electrons. Therefore, they release different types of photons. This results in material-specific wavelength characteristics of the laser beam.
The laser travels to the cutting head through a series of internal optical system. The laser cutting system can move around the workpiece. Therefore, the optical system aims to ensure the required laser focus and diameter remains unchanged. Some laser cutting machines skip on the internal optics and instead add the ability to move the workpiece around a stationary cutting head. The laser is output from the machine through the cutting head. The cutting head contains a high-quality lens to focus the laser beam to a very narrow width.
The laser beam falls on the material at the required spot. The energy from the laser beam is transferred to the material particles. This heats the particles and melts them instantly. The laser works in tandem with the gas assist system that blows the molten material as soon as the laser melts it. This results in the characteristic clean cut of the fiber laser cutting process.
What are Main Fiber Laser Cutting Parameters?
Working with fiber laser technology requires understanding the several parameters associated with the process. These parameters are:
What are the Different Types of Fiber Lasers?
There are many different classification systems for fiber lasers. These are:
Fiber lasers are classified according to the doped materials. Some of these fiber lasers are:
Laser cutting machines have multiple modes of operation, such as:
There are two models of fiber laser cutting based on the far-field distribution characteristics of the laser beam:
What Materials Can a Fiber Laser Cut?
A fiber laser cutting machine can work on a wide range of materials, such as:
Lasers can cut any metals and metal alloys. This includes ferrous and non-ferrous materials. Some examples of metals and alloys that fiber lasers cut are:
A fiber laser can cut through wood without generating any sawdust. The process applies to all types of woods. However, appropriate fire prevention safeguards should be used when cutting wood with a laser cutter. In addition, ensure that the wood does not contain any flammable paints or oils. Some common woods cut by fiber laser cutting machine are:
Lasers can create intricate cuts on paper and products such as cardboard. These capabilities are used in decorative cards and wedding invites.
Plastic cutting is a sensitive area for lasers. It is important to ensure that the fumes generated by the plastic do not cause damage to the fiber laser optics. Therefore, you can cut with a laser with limited choices of plastics and composites. However, fiber laser can cut hard composites like carbon with ease.
Besides the above materials, there are also many more that can be cut with a fiber laser. These are:
What are the Benefits of Fiber Laser Cutting?
Fiber laser cutting provides several advantages when compared with alternative industrial cutting technologies. Some of these are:
Limitations of Laser Cutting
If you want to learn more, please visit our website Single-platform Fiber Laser Cutting Machine.
Laser cutting has a high versatility and is a widely adopted technology. Even so, there can be certain limitations to a fiber laser cutting machine for some users. These limitations are:
How to Choose a Fiber Laser Cutting Machine?
When choosing a fiber laser cutter, evaluate your options based on the following parameters:
What are the Applications of a Fiber Laser Cutting Machine?
A fiber laser cutter is used in a wide range of industries, including:
Are there any challenges of fiber laser cutting?
The main challenge of fiber laser cutting is the thickness of material that can be cut. Laser cutting technologies are good for material sheets but don't work well for thick blocks.
In addition, cutting toxic materials emit gases that settle in the optics and damage them irreversibly.
What maintenance is required for a fiber laser cutting system?
The major maintenance requirement of the laser cutting system is to ensure the cooling system is doing its job. This includes period checks on the filters and level of coolants.
The lens and mirrors also require cleaning to remove any settled dust. A clean fiber optics system will provide a better beam quality.
Are there any environmental considerations or regulations associated with fiber laser cutting?
The main environmental consideration with using fiber laser solution for cutting is the generation of smoke, gases, and aerosols. It is important to check with local rules to know if there are any regulations in the disposal of such waste.
How long does a fiber laser system last?
A fiber laser system can last for over 50 years with proper use and maintenance. This equates to about 100,000 working hours for the machine.
In comparison, CO2 laser cutting machines have a lifespan of only around 10 years.
How much does a fiber laser cutter cost?
The cost of a fiber laser cutter can vary between $30,000 to $500,000. The wide price bracket is due to variances in parameters such as machine features, degree of automation, laser power, etc.
Focusing on the machine quality can provide better results and return on investment instead of sorting products based on the initial cost.
Accurl's fiber laser cutting machines provide the best value for money in this regard. These machines combine a high-quality IPG fiber laser source with a rugged construction. The machine has features such as graphite anti-burn technology to protect every part of the bed and worktable from laser burn. There are many products to choose from in the catalog to suit particular requirements and budgets.
What is the difference between fiber laser technology and CO2 laser?
The difference between fiber laser and CO2 laser is the type of laser system. Fiber laser uses a rare earth material doped fiber optics laser cavity to generate the amplified light beam.
On the other hand, CO2 laser uses a gas discharge tube to produce laser light.
A fiber laser cutting machine is a great way to cut any material without any operating costs involved with tooling or cutters.
Modern fiber laser cutters can cut metals with the hardest machinability. This makes laser cutting solutions an excellent investment for all industrial applications.
If you want to add a laser cutter to your workshop or manufacturing facility, get in touch with Accurl to know the best fit for your requirement.
Frequently Asked Questions
Here are the answers to some common questions regarding laser cutting machines:
The frequency range of fiber laser cutting can vary between 20 KHz to 200 KHz. The useful frequency bracket is quite lower, generally around 50 KHz to 100 KHz. This frequency range depends on the power of the laser being used.
A 1 kW fiber laser can cut material as thick as 20 mm. The maximum thickness depends on the type of material being cut. For instance, while a 1 kW laser can cut 20 mm carbon steel, the maximum thickness for stainless steel is only 10 mm.
In the laser program, the cutting power and cutting speed can be optimized per design or subsection. For example, the cutting speed is usually slower when a small circle or sharp corner is cut. In the program the cutting power can be reduced locally by adjusting the cutting speed so that the cutting precision and quality are perfect everywhere.
Choosing the right auxiliary gases and optimizing the right amount is a difficult job and essential for a good end result.
Optimizing this takes time and experience, which is typically built up by experimenting a lot with different materials, powers, gas pressures and cutting speeds. We try to help you on your way here, we try to answer questions such as:
Auxiliary gases have a number of functions:
Different materials require the use of matching auxiliary gases.
Oxygen is generally used for laser cutting of low-carbon steel sheet. The role of oxygen in the carbon steel cutting process is to fuel and blow off the molten material.
The auxiliary gases commonly used in laser cutting are:
Auxiliary gas pressure and flow requirements are different for materials of different thicknesses and different materials.
Impurities in the auxiliary gas can damage the lens, causing fluctuations in cutting power. In addition, inconsistencies can arise at the top or bottom of the plate material.
Oxygen
The purity of oxygen is generally higher than 99.5%. The higher the purity, the brighter the cutting surface. It is important to note that the oxygen contains impurities, such as water, which can seriously affect the cut quality of the plate surface. If the oxygen purity is not high and the processed parts have higher demands on the surface quality, it is necessary to add oxygen drying equipment and other devices to improve the oxygen purity.
Nitrogen
Nitrogen is mostly used for cutting stainless steel and aluminum alloy materials. The role of nitrogen in the stainless steel cutting process is to eliminate oxidation and blow off the melt. The thicker the plate, the higher the nitrogen pressure required. When cutting stainless steel, the required nitrogen purity is typically higher than 99.999%. Low purity nitrogen can cause yellowing of the cut surface and decrease clarity.
The amount of air pressure that can be used for different types of auxiliary gases is different.
The optimum settings are determined on the basis of the properties of the gas, such as flammability and combustion, and experimentation.
If the auxiliary gas is used to prevent dross formation or to protect the lens, it is roughly the case that the greater the gas pressure, the more metal vapor can be blown away. As a result, it can be cut at a higher speed. This is the function of the use of nitrogen in thin sheet cutting.
This is different for thick sheet material. MetaQuip can help you find the optimal settings for your materials.
For more information, please visit Single Table Fiber Laser Cutting Machine.