Sheet metal cutting with fiber lasers● About Bystronic● Introduction● Results and Discussion● Results and Discussion● Summary
Andreas Lüdi and Stefan WittwerBystronic Laser AG
B t i K FiBystronic: Key Figures
• Established in 1985• Established in 1985
• Field of activity: Sheet Metal Processing Metal Processing Systems
Headq arters• Headquarters:Niederönz (CH)
Si 1994 t f th • Since 1994 part of the Conzzeta Group
• Sales 500 mio. € (2008)
• Employees 1627
© 2009 BystronicSwisslaser.net Workshop Burgdorf 2009 26.11.2009, Folie 2
B t i C A ti itiBystronic: Core Activities
L W t j t Laser Cutting Bending
Waterjet Cutting
• Process chain: cutting - bending
• All from a single source• For all flat materials and
Handling & Software & Services &
all shapes
Automation Control Support
• Automation of the complete mate ials and complete materials and data flow
• For increased productivity
© 2009 BystronicSwisslaser.net Workshop Burgdorf 2009 26.11.2009, Folie 3
and cost efficiency
I t d ti /M ti tiIntroduction/Motivation
Wish list for a laser cutting system
Cost effecti e
CO2 fiber
☺• Cost-effective
• Reliable autonomous operation
• Energy-efficient
☺☺ ☺
☺Energy efficient
• Compact layout
• Simple operation
☺☺☺• Little maintenance
• Continuous high output
Good cut quality
☺☺ ☺
• Good cut quality
Source: PM By
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O ti fi tiOptic configurations
dFiberfC
dFocus=(fF/fC)·dFiber
several optic configurations
350
400
450
um
]
6975100
150 µm
fC [mm]
200
250
300
dia
mete
r [u 100
fF
100 µm
50
100
150
200fo
cal
dFocus
50 µm
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50100 120 140 160 180 200 220
focal length [mm]
dFocus
focal length fF [mm]
C tti lt 2005 Al iCutting results 2005: Aluminum
Aluminium SpeedAluminium
16000
18000
IPG
Bylaser2200
Speed
> 4mm similar to 2 kW CO2
< 4mm faster than 5 kW CO2Fiber 2 kW
CO2 2 kW
Fiber 2 kW
CO2 2 kW
8000
10000
12000
14000
(m
m/
min
)
y
Bylaser4000
Bylaser4400
Bylaser5200
Q lit
CO2 4 kW
CO2 4.4 kW
CO2 5 kW
ng s
pee
d
2
CO2 4 kW
CO2 4.4 kW
CO2 5 kW
2000
4000
6000
8000
Vo
rsch
ub Quality
Similar to CO2. Cutt
in
0
2000
1 1.5 2 3 4 5 6 8
Dicke (mm)Thickness [mm]
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C tti lt 2005 St l (O )
Baustahl
Cutting results 2005: Steel (O2)
SpeedBaustahl
8000
9000
10000
IPG
Bylaser2200
Bylaser4000
Speed
> 5mm similar to 2 kW CO2
< 5mm similar to 5 kW CO2
Fiber 2 kW
CO2 2 kW
CO2 4 kW
5000
6000
7000
b (
mm
/m
in)
Bylaser4000
Bylaser4400
Bylaser5200
Quality g s
pee
d
2
CO2 4.4 kW
CO2 5 kW
2000
3000
4000
Vo
rsch
ub Quality
< 6mm very good
> 6mm good
Cutt
ing
0
1000
1 2 3 4 5 6 8 10 12 15 20
Dicke (mm)Thickness [mm]Dicke (mm)Thickness [mm]
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C tti lt 2005 St i l t l
Edelstahl
Cutting results 2005: Stainless steel
Edelstahl Speed
11000
12000
13000
14000
IPG
Bylaser2200
Bylaser4000
B l 440011000
12000
13000
14000
IPG
Bylaser2200
Bylaser4000
B l 4400
Speed
> 4mm similar to 2 kW CO2
< 4mm faster than 5 kW CO2
FaserlaserFiber 2 kW
CO2 2 kW
CO2 4 kW
CO 4 4 kW
7000
8000
9000
10000
b (
mm
/m
in) Bylaser4400
Bylaser5200
7000
8000
9000
10000
b (
mm
/m
in) Bylaser4400
Bylaser5200
Qualityng s
pee
d
CO2 4.4 kW
CO2 5 kW
3000
4000
5000
6000
Vo
rsch
ub
3000
4000
5000
6000
Vo
rsch
ub Quality
Rather rough cut,
worse than CO2
Cutt
in
0
1000
2000
1 1.5 2 3 4 5 6 8Dicke (mm)
0
1000
2000
1 1.5 2 3 4 5 6 8Dicke (mm)Thickness [mm]Dicke (mm)Dicke (mm)Thickness [mm]
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C tti lt 2005 St i l t lCutting results 2005: Stainless steel
fiber laser: 4mm stainless steelrough cut; Rz ~ 30 µm (lower region)
fiber
CO2 laser: 4mm stainless steelsmooth surface with Rz < 10 µm
CO2
Rz<10 µm
CO2
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C tti ibiliti Fib CO2Cutting possibilities: Fiber vs. CO2
Fiber laser cuts fasterG d t lit l ith
N2 Comparable cut quality of fiber- and CO2-laser
Good cut quality only with CO2-laser
Comparable cutting speed of CO and fiber laser O2 Comparable cutting speed of CO2 and fiber laser
Comparable cutting quality of CO2 and fiber laser
5mm - 20mm1mm - 5mm© 2009 BystronicSwisslaser.net Workshop Burgdorf 2009 26.11.2009, Folie 10 comparison with equal optical power / Source: Optech Consulting, 2009
Sit ti t dSituation today
Today most fiber laser cutting machines are Today, most fiber laser cutting machines are used for thin sheets.
-ByVention Fiber 2 kW2007 Munich(presented on Laser 2007 WORLD
OF PHOTONICS, Munich)
-several fiber laser cutting machines have beenpresented on Euroblech 08 Hannover
© 2009 BystronicSwisslaser.net Workshop Burgdorf 2009 26.11.2009, Folie 11
presented on Euroblech 08, Hannover.
h t i t lit an approach to improve cut quality
Laser beam
a.U
.]rp
tion [
aAbso
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Angle of incidence v [deg]
A l f i idAngle of incidence
Laser beam Laser beam Laser beam
Dsheetsheet
v i =Dsheet
Dtan-1( )
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vmin DLaser beamta ( )
A l f i id h t thi kAngle of incidence: sheet thickness
]on [
a.U
.]Abso
rpti
Angle of incidence v [deg]
v i =Dsheet
Dtan-1( )
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vmin DLaser beamta ( )
A l f i id b tiltiAngle of incidence: beam tilting
85Blechdicke=4mm, Durchmesser Strahl=0.4 mmDsheet=4 mm, DLaser=0.3 mm
84 8
84.9
84.7
84.8
wdeg
]
84.5
84.6
Win
kel
Angle
v [
d
84.3
84.4
70 75 80 85 90 95 100 184.2
Winkel aAngle a [deg]
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A l f i id l t d bAngle of incidence: elongated beam
U.]
ption [
a.U
Abso
rp
D
Angle of incidence v [deg]
© 2009 BystronicSwisslaser.net Workshop Burgdorf 2009 26.11.2009, Folie 16
vmin=Dsheet
DLaser beamtan-1( )
A l f i id f l itiAngle of incidence: focal position
Extreme focal positionp
U.]
ption [
a.U
Abso
rp
Angle of incidence v [deg]
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C t lit i tCut quality improvements
Standard cut (@2kW) Cut with extreme focal position (@2kW)
26.1 µm 16.9 µm
6m
m
47.3 µm 21.7 µm
301;
D=
6
70.2 µm 28.0 µm1.4
3
Reduced burrsReduced roughness
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Reduced roughness
SSummary
- 1µm lasers have inherent disadvantage concerning fusion cutting of thick sheet metals [a
.U.]
concerning fusion cutting of thick sheet metals (and v.v. concerning thin sheet metals)
Abso
rption
- Improvements of cut quality can be achieved Angle of incidence v [deg]
by improved incoupling of laser radiation
Thank you for your attention
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