Laser cutting allows for greater reliability and efficiency across multiple industrial applications. The term “laser” is actually an acronym for "light amplification by stimulated emission of radiation.” Fiber-optic laser cutting is commonly used for parts manufacturing and other industrial applications and employs high-powered beams with short wave lengths that slice through tube, pipe or flat sheet. Shorter wave lengths are key to more efficient and faster cutting speeds, as these allow for greater absorption into metals.
Why Utilize Laser Cutting?
There are many reasons for utilizing laser cutting. For one, some materials, due to their shape or type of metal, are difficult or even impossible to cut using traditional methods. Laser cutting, however, can handle multiple shapes and highly reflective materials.
A wide range of industries utilize laser cutting due to its ability to process parts easier. It is requested by manufacturers in the aerospace and automotive industries. Laser cutting is also ideal for parts needed in high sanitary environments such as medical device and food and beverage equipment settings, as the process ensures both precision and the reduced risk of contamination, given the minimal contact needed.
Additionally, a laser delivers a cleaner edge. This reduces the need for deburring or other finishing techniques otherwise used to clean up parts after cutting—common with conventional machines. Secondary operations are thus streamlined, while the process guards against inconsistencies that can arise from the manual grinding or smoothing.
Laser cutting also accommodates complex machining, incorporating numerous manual operations into a single automated process. For example, a part can be bent and then easily laser cut, sometimes on the same machine. Compared to manual or traditional operations, this ensures lower set-up time and in turn, reduced labor costs.
In addition to being maintenance-free with a long service life, fiber lasers are known for their energy-efficiency. Moreover, the laser cutting process is much safer than other forms of cutting, as the laser beam is emitted securely within a tight light box, offering a heightened level of security and reliability for the operator.
From a labor perspective, once a laser is set up to start a job, there is little supervision required by the machine operator until the process is complete. This frees up technicians to perform other tasks within the facility.
Laser Cutting Applications
Laser cutting is ideal for many types of metals, particularly aluminum and mild to high-strength steel and stainless steel. This method also works well with brass, copper or bronze, as the laser beam easily absorbs into the metal instead of bouncing off its surface.
The higher power density of the focused beam paired with the absorption of the fiber wavelength accelerates the cutting speed for materials that are less than 1/8” thick. Although fiber lasers can cut thicker materials at an accelerated rate, the most ideal size for fiber laser cutting are materials at or below 1/8”, compared to CO2 lasers.
How Laser Cutting Works
Looking at the process of how laser cutting works, light-emitting diodes create a focused beam of light, or photon, which raises the material’s temperature above its melting point to create the cut. While this is happening, high-pressure nitrogen sweeps the particles of molten metal out of the kerf, which is the area of the material that is burned away at the focal point of the beam.
Making cut specifications is a simple matter of raising or lowering the focal point of the beam. The beam can be aimed right above the surface of the plate, at the surface, or right below the surface.
With laser cutting, the wattage used is significant. For instance, a 4,000-watt laser can cut up to .75-inch metal, while a 6,000-watt laser can accommodate an additional half inch
Examples of laser cut parts in various thicknesses are available here.
Using Laser Cutting for Different Shapes and Sizes
Using a laser allows for greater flexibility when it comes to different shapes and sizes. Among its greatest advantages is its ability to create just about any shape needed. There are few limitations to this advantage, apart from the size of the part needing to be able to fit within the clamp and in the machine cabinet. Additionally, one can easily adjust the sizing of the shape on-machine and does not require additional tooling.
For those looking to produce holes significantly smaller than the thickness of the substrate, fiber lasers are ideal as they produce a very tight focal spot diameter—up to 100 times smaller compared to the CO2—unlike many mechanical cutting processes.
Laser cutting allows for greater precision as the beam does not wear during the process. Also, laser systems have a small heat-affected zone, which means the beam hits a small and highly targeted portion of the metal. This reduces the chance that the material being cut will warp.
Conclusion
Overall, laser cutting can offer peace of mind for manufacturers seeking a consistent and reliable process for their parts production. For more information on laser-cutting, please click here.
About Sharpe Products
Founded in 1990, Sharpe Products provides custom pipe and tube bending, laser cutting and custom fabrication services for commercial and industrial applications.
More information is available at sharpeproducts.com.
This blog was authored by Marshall Arndt, Estimating Engineer, Sharpe Products. Marshall can be reached at marshalla@sharpeproducts.com
