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Vernier Caliper
Laser Cutting Machine Fundamentals
Laser cutters operate by focusing a beam of light, or laser, on a pinpointed site on an object in order to cut it rather than using a solid object, like a blade, to cut the object. A computer system with vector graphical software will also be needed. Instructions are given to the laser cutter through software which deciphers design geometry to numerical CNC machine code. A laser can also take in data from drawings made with the help of computer-aided design (CAD) software.
Configurations of Laser Cutting Machines
The configurations of the machine are characterized based on the way the laser beam will come in contact with the material that will be cut. There are three main setups that work on the X and Y axes. The first configuration is referred to as moving material. In this setup, the object that will be sliced is placed below the cutter head. The next setup is the hybrid laser. Both the table and the cutter head move in opposite axes, offering optimal stability of the beam’s path. The third configuration is the flying optic setup, used by Maloya, where the cutting head is the part of the machine that is in motion. The object being cut is static and this type of configuration produces very clean work. Its rate of motion is also the quickest among the three setups. The flying optic system helps in workflow speed since clamping of the material being cut is not necessary. There are also machines utilizing up to six axes.
Laser Cutting Workflow
Loading and unloading can take up valuable production time but the speed of cutting with a laser can make up for this. Not having to clamp down the materials to be cut in some instances also saves time. Another consideration is if the laser cutter can be left on. Workers may have to turn turn off the power to take materials out of the machine and interrupt the flow of cutting.
Lighting is another consideration in a manufacturing environment. Light emitting diode (LED) lighting is becoming more popular for saving energy. More green ways of lighting manufacturing environments are becoming available such as using motion sensors so lights are not used when no one is working.
Laser Cutting Equipment and Maintenance
With the money spent on laser cutting machines, sufficient upkeep can ensure that they keep running in a safe and reliable way. If the machine is not running optimally, bad cuts can be made. Process control such as checking cutting nozzles, lenses and other optics should be conducted regularly. Conducting frequent inspections on alignment can prevent many future problems. Air sources can affect focal lenses of the laser cutter. Lens clarity is extremely important. Operators can look at a focal lens and tell if it is dirty as well as by checking it with a polarizer. A lens can then be cleaned with alcohol and fine tissue or replaced. Laser optical components are considered consumables. Chiller units need to be maintained as well. They should be started prior to cutting. A laser cutter that has not been maintained will also run slower. Replaceable parts should also be kept available if they are needed. Keep exhaust systems up to par as well.
Laser Cutting and Training
Training of use of a laser cutting machine should include hands-on training as well as additional training in a classroom environment. It should involve basic operation of the laser cutter such as how to start and shut down the machine, operation and programming of the machine, upkeep and maintenance as well as safety. Oftentimes the purchaser of the machine will receive training from the supplier of the machine. Other training could include the creation and loading of drawings, scaling, and rotation. Other things to be learned are file usage, code, databases, laser tables and metrics. CAD and computers need to be comprehended to use a laser cutter. One should understand how to measure materials’ thicknesses in relation to whether the laser cutters can cut them effectively. Blueprint reading should also be a skill held by a laser cutter user. Users need to be educated in quality control and geometric tolerance to know the range of precision of a laser cutter. Material Requirements Planning (MRP) involves planning everything needed for a job as well as inventory taking. Software is used for these tasks. Proper training on these systems is key as the common problem with them is the data often is erroneous. Some of these errors can be taken care of through proper teaching.
One should be able to use measuring tools such as calipers or a vernier caliper which can offer more accurate measurements. Other basic tools someone should be skilled in the use of are a ruler, protractor, compass and basic mathematical tools.
Quality Control
In order to keep improving workflow processes, Corrective Action Requests (CARs) and Corrective Action Notifications (CANs) can be done. This involves problem reporting, the cause of the problem, and future problem preventions. Software can take care of these issues and is called workflow quality management software. For instance, if one event occurs, a notification in a certain form such as an email will go out to a person who handles that problem. The action will then be taken to correct the problem.
Much knowledge and skill is required in operating a laser cutter. Having the wherewithal to operate the machine properly in a proper environment will keep a machine working efficiently on many projects for a long time to come.
About the Author
Roger Hug is the VP of Sales Engineering of Maloya Laser, leaders in contract manufacturing and turnkey manufacturing servicing aerospace, scientific, transportation, medical and machinery needs.
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