Laser Cutting technology has become widely used in sheet metal processing, especially for small-batch, diversified product demands. This technique, known for its high precision and efficiency, is now extensively applied, particularly in industries such as housing cabinets, home appliances, hardware products, instruments, signage, and lighting fixtures. In recent years, our company has focused on expanding the optical disc storage industry, where the core sheet metal components require highly precise dimensions (±0.1mm). For this purpose, we introduced the AMADA fiber laser punching composite machine, which offers a cutting precision of ±0.07mm/1000mm. However, during practical Laser Cutting processes, issues like cutting waves and burrs often occur, especially in large-sized products, with defect rates reaching up to 10%, seriously affecting product quality and production costs.

Current State of Cutting Waves in Laser Cutting

When using the composite machine for Laser Cutting, the machine’s clamps move the sheet metal along the X and Y directions. However, as the process progresses, local stress in the sheet metal gradually releases, leading to a decrease in the overall structural strength of the material. This results in vibrations during the motion, which subsequently creates cutting waves. This issue is more prominent when processing large components, as stress release is more significant and vibration is exacerbated, worsening the cutting quality. Therefore, maintaining the structural stability and strength of the sheet metal during Laser Cutting is key to preventing wave formation.

Key Factors Affecting Cutting Waves and Optimization Strategies

1. Starting Position of the Workpiece

The starting position for Laser Cutting significantly impacts the distribution and stability of stress in the sheet metal. The starting position can generally be either “away from the clamp end” or “close to the clamp end.” Starting the cut from the end farthest from the clamps can effectively retain the material strength in the clamped area, delaying stress release and enhancing sheet metal stability, which reduces the chances of cutting waves. Conversely, starting from the clamp end causes a rapid decline in material strength as the cutting progresses, leading to instability and vibrations that result in cutting waves. Therefore, programming should prioritize starting cuts away from the clamp end and gradually work inward.

2. Entry Point and Cutting Direction

Unter Laser Cutting, the choice of entry point directly affects the stability of the cutting path. A proper entry point and cutting direction can significantly reduce the risk of cutting waves. In the later stages of the process, when the material strength decreases, setting the entry point in the middle of the component, regardless of the cutting direction, can lead to early separation at the bottom and increased stress release, resulting in localized waves. Setting the entry point at the bottom end and aligning the cutting direction so that the clamp end is cut last can help maintain the stability of the sheet metal, optimizing the Laser Cutting quality.

3. Clamp Positioning

The clamps not only drive the movement of the sheet metal but also play a critical role in maintaining the stability of the process. Clamp layout should be even and reasonable to avoid imbalance in the sheet metal. Although this factor is controllable, improper clamp positioning can still lead to unnecessary sheet metal vibration during Laser Cutting, inducing waves. Therefore, properly setting the clamp positions is a fundamental step in improving the stability of the Laser Cutting Prozess.

4. Extraction Sequence

In automated production, using a TK robotic arm for part extraction can improve efficiency, but improper extraction sequence can severely impact subsequent Laser Cutting quality. If parts from both ends of the sheet are extracted first, it concentrates the stress release in the middle, causing serious vibrations and waves due to insufficient strength in the middle. The correct approach is to extract parts sequentially from the farthest end from the clamps, maintaining stress concentration and structural stability, thereby reducing vibration and cutting waves in later Laser Cutting stages.

Abschluss

In conclusion, cutting waves generated during Laser Cutting are not caused by a single factor but are the result of the combined effects of factors such as the starting position, entry point, clamp layout, and extraction sequence. Additionally, they are closely related to the size, weight, and cutting speed of the parts. To effectively suppress cutting waves in actual production, these factors must be systematically considered in programming and operation, and comprehensive control strategies must be implemented. Only by fully optimizing the Laser Cutting process can we continuously improve product quality, reduce defect rates, and achieve high-precision, low-cost sheet metal processing goals.