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LASER BLANKINGIncreased flexibility and efficiency
for your production strategy
LASER BLANKING| 2
INDEXFAGOR ARRASATE
LASER BLANKING LINE CONCEPT
LASER BLANKING ADVANTAGES
PRODUCTIVITY
CUTTING QUALITY
NESTING & STACKING FLEXIBILITY
REDUCING TIME TO MARKET
LASER BLANKING| 3
FAGOR ARRASATE designs, manufactures and supplies Presses
and Stamping Systems, Metal and Composites Forming
Solutions, Coil Cutting and Processing Lines as well as complete
Installations to manufacture Complex Sheet Metal Parts.
FAGOR ARRASATEIN FIGURES
215 MM€ turnover in 2019
850 employees
Exports 85% of its sales
8 manufacturing and assembly facilities
First-class customers
More than 60 years of experience
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FAGOR ARRASATEPRODUCTS
• High Speed Lines
• Transfer presses
• Press Hardening
• Blanking lines
• Composites
• Forging systems
• Tryout presses
AUTOMOTIVE
• Cut-To-Length lines
• Slitting lines
• Press blanking lines
• Laser blanking lines
• Stackers
• Leveler
METAL
Current situation: Under construction
FAGOR ARRASATECLOSER THAN EVER
Operational by mid 2021
We are establishing a new Service facility in Portage.
LASER BLANKING LINE CONCEPT
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EntryDecoiler / Feeder / Straightener / Shear
Cutting CellUp to 3 laser heads
6 KW
Stacking system
PREMIUMLASER BLANKING
LevelerFor steel and aluminum
Cassette extraction
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Cleaning system
Cutting CellContinuous Combined Cutting
2100 wide and 1500mm telescopicityconveyor
Shear drum
PREMIUMLASER BLANKING
Inspection
Stacking systemStacker with lineal robots
with automated flexible gripper
LASER BLANKING ADVANTAGES
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• Increased flexibility:
✓ Manufacturing of complex geometry.
✓ Dies geometrical constraints disappear.
LASER BLANKINGADVANTAGES
• Production is not stopped:
✓ The absence of dies makes possible
almost immediate change of production.
✓ If the material and thickness matches the
same coil can be used by adjusting the nesting.
✓ Not required a specific coil per each die as
in a press blanking process.
✓ Fast change over, just recipe change on the cutting
software, no die changing time dependent from die logistics.
• No cutting Dies required
✓ Significant savings over the life of the
installation
✓ Car model restyling's every 2-3 years, car new
model every 5 years approx., requires new dies
✓ More car models than ever, introduction of the
electric vehicle
✓ More models, smaller batches to amortize the
investment in dies
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• Material mix:
✓ Galvanized Steel
✓ Hot stamping materials (Usibor, Ductibor.. )
✓ High strength steels
✓ Stainless Steel
✓ Aluminum.
✓ Other less conventional materials: Cupper, brass…
• Laser cutting is not conditioned by the material strength.
LASER BLANKINGADVANTAGES
• Increased adaptability:
✓ In a conventional blanking line in case of a die breakage,
the production can no longer continue.
✓ Capability of producing any part at any moment at a facility
equipped with a laser blanking, just the CAD drawing is
required.
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LASER BLANKINGADVANTAGES
• Reduction of production costs:
✓ Fully optimized use of material, the amount of scrap is
reduced.
✓ No need for previous edge trimming process to adapt the
coil width to the die.
✓ Lower energy consumption than a conventional press blanking
✓ Less personnel required, associated to die logistics.
• Reduction of maintenance costs:
✓ Maintenance cost, huge savings.
✓ Unlike conventional press and dies, maintenance complex operations are
avoided, qualified personnel for die fixing is not required anymore.
✓ Due to high strength steels, faster die wearing.
✓ Aluminum processing requires more frequent knives cleaning.
✓ Less maintenance (time) and less expensive, not so costly consumables.
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LASER BLANKINGADVANTAGES
• Reduced cost of installation:
✓ Significant savings in foundation costs, estimated over 600.000€.
✓ No pits are required, nor reinforced floor for the press efforts.
✓ No need to build high bay workshops.
✓ Not required high load overhead cranes for die logistics.Conventional blanking
Laser blanking
• Reduction of space:
✓ Die storage/maintenance area is not required.
✓ Significant space saving, around 400m2.
PRODUCTIVITY-STUDY OF CUTTING TIMES
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Aprox. Up to 25 parts/min.
Inner parts (A-pillar, B-pillar,….)
Radials, Omegas, Trapezoids, ...
Aprox. Up to 35 parts/min.
Aprox. Up to 10 parts/min.
CONCLUSIONS REGARDING PRODUCTIVITY
Large panels (side panel, upper gate, ...)
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Lets take a closer look to some hot stamping parts
CONCLUSIONS REGARDING PRODUCTIVITY
Part Data Cutting parameters 3 Cutting Heads
Description MaterialThickness
(mm)Width(mm)
Pitch(mm)
Laser Power(KW)
Speed(m/min)
Part/Step Parts/min
B-Pillar Steel 1,4 1540 874 6 4,9 2 11,21B-pillar simplified Steel 1,4 1380 785 6 8,1 2 20,64A-Pillar Steel 1,2 1630 306 6 4,5 1 14,71A- Pillar simplified Steel 1,5 1120 215 6 6 1 27,91B-Pillar Steel 1,5 1354 840 6 7,3 2 17,38A-pillar Steel 1,3 1761 234 6 3,9 1 16,67B-pillar Steel 2 1392 960 6 5,1 2 10,63A-Pillar Steel 1,2 1060 157 6 2,1 1 13,38B-pillar Steel 1,5 1354 840 6 7,3 2 17,38
AVERAGE 16,65
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Optimizations due to modifications in blank geometry:
✓ Modifying the path slightly in non critical points lead to a productivity increase of %44 in this case.
✓ In this case deviating up to 1,77mm in small areas from the original shape.
CONCLUSIONS REGARDING PRODUCTIVITY
CUTTING QUALITY
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CUTTINGQUALITY
• Laser cutting results:
✓ Single cutting ± 0.4mm
✓ Combined cutting ± 0.7mm
✓ Linearity: <0,1mm/m
✓ Burr: < 5% (nearly zero in some cases)
• Wide library of cutting set-up for different material-thickness couples
✓ Optimum cutting conditions achieved for the best cutting quality.
✓ Parameters , stand-off, gas assist pressure, focal length…
✓ Library based on empirical values available with the software.
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B-pillar
Measured by a three-dimensional measurement device and compared
with original DXF.
Max. deviation measure= -0,35/+0,1mmMax. deviation in hole= -0.16/+0.016
CUTTINGQUALITY
Combined cutting
Max. Deviation measure= -0,68/+0,35mmMax. deviation in hole= -0.18/+0.34
Single cutting
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What about Taylor welded blanks?Does the laser cutting technology fullfil the requirements??
Max. Deviation measure= -0,5/+0,4mmMax. deviation in hole= -0.139/ 0Linearity= -0 / -0,08
CUTTINGQUALITY
TAILOR WELDED BLANKS
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Max. Deviation= -0,22/+0,35mmMax. deviation in hole= -0.148/ -0.07
Linearity= 0.01 / 0,09
CUTTINGQUALITY
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Die cutting profile Laser edge quality
CUTTINGQUALITY
• Cutting edge quality:
✓ Conventional die cutting edge shape disappears.
✓ Edge microcracks do not occur as in conventional shearing process,
specially for high strength steels.
▪ This could lead to blank fractures in following stamping
processes!!!
✓ Less burr than in conventional cutting process.
▪ Burr excess, in case that is released may get adhered on the
stamping die and generate marks in case of cold stamping.
▪ Burr excess plus oiled blanks may cause difficulties on the
destacking process previous to forming.
✓ Aluminum cutting in conventional die cutting process, material
adheres to the knives (aluminum oxide), what generates edge quality
deterioration and increasing burr. Production interruption.
✓ Optimal cutting control systems are integrated in the laser
head.
▪ Ceramics breakage detection
▪ Window dirtiness detection
Before the edge quality gets worse the system will warn in
order to avoid further consequences.
• Leveling :
✓ Leveling process is also determinant to guarantee a high quality
cut blanks.
✓ Undulations on the strip due to a
poor leveling, force the system to
a continuous stand-off height
positioning, with consequences on
the cut edge.
✓ Additionally, blanks without internal stresses have a better
behavior at stamping process (cold in this case).
✓ High leveling requirements are no necessary for hot stamping.
CUTTINGQUALITY
Stand off control
NESTING&
STACKING FLEXIBILITY
The nesting software allows:
✓ Preparation of the blank nesting in accordance with the available
coil reducing to a maximum the scrap material (compromise
between productivity and scrap).
▪ Different references could be cut at the same time, by defining
a multipiece nesting.
✓ Divide cutting operations between the different laser heads to
optimize productivity. Simulation or display of movements.
✓ CNC programs generation and communication with HMI of the line.
NESTINGFLEXIBILTY
Throughput: 30pieces/min
Material utilization: 74%
Throughput: 28pieces/min
Material utilization: 87%
Nesting examples: Maximum material utilization
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STACKINGFLEXIBILITY
Hot stamping blanks disposal Blanks reorientation Vacuum cups positioning adjustability
The stacker allows:
✓ Presetting the vacuum cups of the gripper (flexible), and management of the
manipulation of the blanks in the stacking area, is communicated with the
nesting.
✓ Picking blanks on the fly.
✓ Picking multiple parts at the same time and locate them in different positions.
✓ Parts reorientation.
• Bundles relocating process for the destacker previous to the hot stampingprocess could be saved, working together with multipiece nesting.
REDUCING TIME TO MARKET
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Laser technology in the launching process:
✓ Blanking die design and manufacturing are not required so the
launching process is shorten several months.
✓ The industrialization of the part is an iterative process until the
optimum is achieved. Drawings for laser blanking can be modified
as many times as wished with a bare impact in time in the tryout
process.
✓ Very appropriate for the actual scenario: increasing car models,
irruption of EV.
REDUCING TIME TO MARKET
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Process optimization:
✓ Geometrical modifications are really easy to carry out during production as well.
▪ Optimization of the forming process is still possible unlike in conventional
blanking:
✓ Looking for better formability.
✓ Material saving.
✓ In a few minutes the new CAD drawing could be modified and executing the new
blank.
✓ Do not require stops in the production process: TIME SAVING.
✓ Additionally, the 3D laser trimming is a bottle neck in the hot stamping process
(piece by piece):
▪ By geometrical modifications and helped by the good tolerances of laser
blanking, the laser trimming area could be reduced in non critical points:
TIME & COST SAVING.
REDUCING TIME TO MARKET
Laser trimming process
THANK YOUESKERRIK ASKO
GRACIAS
Ion Mendia Product Manager, Blanking, Laser Blanking and Cut-to-Length Lines, Fagor Arrasate S. Coop.@ i.mendia@fagorarrasate.comTel.: +34 661 684 287
Mathew MitchellNational Sales ManagerFagor Arrasate USA Inc @ m.mitchell@fagorarrasate.comTel: +34 661 684 287
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