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Laser cutting sheet metal
WANDA-AN
sm-AL010-001
|
Product Description
Laser cutting involves precise control of laser parameters, material handling, and post-processing to achieve high-quality cut.
How Laser Cutting Work ?
Laser Generation: A high-powered laser beam (CO₂, fiber, or Nd:YAG) is generated and focused onto the sheet metal.
Melting/Vaporization: The intense heat melts or vaporizes the material along the programmed path.
Assist Gas: A jet of assist gas (oxygen, nitrogen, or air) blows away molten material, ensuring a clean cut.
CNC Precision: Computer Numerical Control (CNC) guides the laser head for intricate designs with tight tolerances (±0.1mm or better).
1. Pre-Processing Steps
A. Material Preparation
Sheet Flatness: Ensure the sheet is flat (no warping) to maintain consistent focus.
Surface Cleaning: Remove oil, rust, or coatings to prevent uneven cuts and reflections.
Fixturing: Secure the sheet with clamps or magnetic beds to avoid vibrations.
B. CAD/CAM Design & Programming
Design File (DXF, DWG, STEP): Create or import the part geometry.
Nesting Optimization: Arrange parts to minimize material waste.
Cutting Parameters: Set laser power, speed, frequency, and gas pressure based on material/thickness.
2. Laser Cutting Process
A. Laser Beam Generation & Focusing
Laser Source:
Fiber Laser (1µm wavelength) – Best for metals (fast, precise).
CO₂ Laser (10.6µm) – Better for thicker metals and organics.
Focusing Lens: Concentrates the beam to a fine spot (0.1–0.3mm diameter).
Nozzle Alignment: Ensures assist gas flows uniformly (prevents dross).
| Common Defects & Solutions | ||
| Defect | Cause | Solution |
| Burrs | Low gas pressure | Increase N₂/O₂ flow. |
| Dross | Slow speed, wrong gas | Optimize speed, use N₂ for SS. |
| Overburning | Excessive power | Reduce laser wattage. |
| Warping | Heat buildup | Use pulse cutting, heat sinks. |
| Incomplete Cut | Too fast, low power | Adjust feed rate/power. |
|
Product Details
Advantages of Laser Cutting Sheet Metal
*High Precision: Cuts complex geometries with sharp edges and minimal kerf.
*Speed: Faster than plasma or waterjet for thin to medium sheets.
*Material Versatility: Cuts steel, stainless steel, aluminum, brass, copper, and more.
*Minimal Waste: Narrow laser beam reduces material loss.
*No Tool Wear: Non-contact process avoids mechanical degradation.
Common Laser Types for Sheet Metal
Fiber Lasers: Best for thin to medium metals (up to 30mm), energy-efficient, high speed.
CO₂ Lasers: Suitable for thicker materials (up to 25mm) and non-metals.
Nd:YAG Lasers: Used for high-reflectivity metals like aluminum.
| Materials & Thickness Limits | |
| Material | Max Thickness (Fiber Laser) |
| Mild Steel | 20–25 mm |
| Stainless Steel | 15–20 mm |
| Aluminum | 12–15 mm |
| Copper/Brass | 8–10 mm |
| Cutting Parameters by Material | ||||
| Material | Power (W) | Speed (m/min) | Assist Gas | Pressure (Bar) |
| Mild Steel | 1000–6000 | 2–10 | O₂ (Oxidation) | 4–10 |
| Stainless | 1000–4000 | 1–6 | N₂ (Clean cut) | 8–16 |
| Aluminum | 2000–6000 | 1–4 | N₂ | 10–20 |
| Copper/Brass | 1500–4000 | 0.5–3 | N₂ | 10–15 |
| Standard Sheet Metal Materials for Laser Cutting | |||
| Material | Common Grades | Thickness Range (mm) | Key Properties |
| Mild Steel | AISI 1008, 1010, 1018 | 0.5 – 25 | Low cost, good weldability |
| Stainless Steel | 304, 316, 430 | 0.5 – 20 | Corrosion-resistant, smooth edges |
| Aluminum | 5052, 6061, 6082 | 0.5 – 15 | Lightweight, reflective (needs N₂) |
| Copper | C110, C101 (Electrolytic) | 0.5 – 10 | High conductivity, reflective |
| Brass | C260 (Cartridge Brass) | 0.5 – 8 | Decorative, requires N₂ assist gas |
| Galvanized Steel | DX51D, DX52D | 0.5 – 12 | Zinc-coated, emits toxic fumes |
|
Assemble & Packaging
1. Assembly Processing
A. Deburring & Edge Smoothing
Methods:
Vibratory Tumbling: For small parts in bulk.
Manual Grinding/Sanding: For precision edges.
Laser Deburring: High-precision edge cleaning.
Purpose: Remove sharp edges (burrs) for safety and fitment.
B. Forming & Bending
Press Brake Bending: CNC-controlled for accurate angles.
Bend Allowance Calculation: Compensates for material stretch.
Tool Selection: V-die width depends on material thickness.
Roll Forming: For curved parts ( cylinders).
| C. Joining Methods | |||
| Method | Best For | Pros | Cons |
| Welding | Structural joints (steel) | Strong, permanent | Heat distortion, HAZ |
| Riveting | Non-weldable metals (Al) | No heat, removable | Less aesthetic |
| Adhesives | Lightweight assemblies | No deformation, smooth finish | Lower strength |
| Fasteners | Serviceable parts | Easy disassembly | Adds weight |
D. Surface Finishing
Powder Coating: Durable, corrosion-resistant, color options.
Anodizing (Aluminum): Improves hardness & corrosion resistance.
Plating (Zinc, Nickel): Enhances conductivity & wear resistance.
Painting: For aesthetic or protective purposes.
E. Inspection & Quality Control
Dimensional Checks: Calipers, CMM (Coordinate Measuring Machine).
Weld Integrity: X-ray or ultrasonic testing (critical applications).
Surface Defects: Visual inspection for scratches/dents.
2. Packaging Methods for Sheet Metal Parts
A. Protective Packaging
Foam Inserts: Prevents scratches during transit.
Edge Guards: Cardboard/plastic protectors for sharp edges.
Anti-Corrosion Measures:
VCI (Vapor Corrosion Inhibitor) Paper: Releases anti-rust vapors.
Desiccant Packs: Absorbs moisture in sealed packages.
| B. Packing by Part Type | |
| Part Type | Packaging Method |
| Flat Parts | Stacked with separator sheets |
| Bent/Folded | Custom foam or molded trays |
| Small Components | Plastic bags (ziplock/bubble wrap) |
| Large Assemblies | Wooden crates with padding |
C. Shipping Considerations
Pallets: Standard 1200×800 mm (EU) or 48×40" (US).
Weight Distribution: Avoid overloading to prevent bending.
Labeling:
Fragile Stickers for delicate parts.
Part Numbers & QTY for easy identification.
| 3. Common Defects in Assembly & Packaging | ||
| Issue | Cause | Solution |
| Scratches/Dents | Poor handling | Use protective films/foam |
| Rust Formation | Humidity exposure | VCI paper + desiccants |
| Misaligned Parts | Incorrect fixturing | Check jigs before assembly |
| Bent Edges in Transit | Insufficient support | Reinforce packaging with foam |
4. Automation in Assembly & Packaging
Robotic Welding: For high-volume production.
Automated Conveyor Systems: Moves parts between stations.
Vision Inspection Systems: Detects assembly defects.
Final Checklist Before Shipment
*All parts deburred & cleaned
*Assembly meets tolerances
*Surface treatment applied (if needed)
*Packaging prevents damage
*Labels & documentation included
|
Product Description
Laser cutting involves precise control of laser parameters, material handling, and post-processing to achieve high-quality cut.
How Laser Cutting Work ?
Laser Generation: A high-powered laser beam (CO₂, fiber, or Nd:YAG) is generated and focused onto the sheet metal.
Melting/Vaporization: The intense heat melts or vaporizes the material along the programmed path.
Assist Gas: A jet of assist gas (oxygen, nitrogen, or air) blows away molten material, ensuring a clean cut.
CNC Precision: Computer Numerical Control (CNC) guides the laser head for intricate designs with tight tolerances (±0.1mm or better).
1. Pre-Processing Steps
A. Material Preparation
Sheet Flatness: Ensure the sheet is flat (no warping) to maintain consistent focus.
Surface Cleaning: Remove oil, rust, or coatings to prevent uneven cuts and reflections.
Fixturing: Secure the sheet with clamps or magnetic beds to avoid vibrations.
B. CAD/CAM Design & Programming
Design File (DXF, DWG, STEP): Create or import the part geometry.
Nesting Optimization: Arrange parts to minimize material waste.
Cutting Parameters: Set laser power, speed, frequency, and gas pressure based on material/thickness.
2. Laser Cutting Process
A. Laser Beam Generation & Focusing
Laser Source:
Fiber Laser (1µm wavelength) – Best for metals (fast, precise).
CO₂ Laser (10.6µm) – Better for thicker metals and organics.
Focusing Lens: Concentrates the beam to a fine spot (0.1–0.3mm diameter).
Nozzle Alignment: Ensures assist gas flows uniformly (prevents dross).
| Common Defects & Solutions | ||
| Defect | Cause | Solution |
| Burrs | Low gas pressure | Increase N₂/O₂ flow. |
| Dross | Slow speed, wrong gas | Optimize speed, use N₂ for SS. |
| Overburning | Excessive power | Reduce laser wattage. |
| Warping | Heat buildup | Use pulse cutting, heat sinks. |
| Incomplete Cut | Too fast, low power | Adjust feed rate/power. |
|
Product Details
Advantages of Laser Cutting Sheet Metal
*High Precision: Cuts complex geometries with sharp edges and minimal kerf.
*Speed: Faster than plasma or waterjet for thin to medium sheets.
*Material Versatility: Cuts steel, stainless steel, aluminum, brass, copper, and more.
*Minimal Waste: Narrow laser beam reduces material loss.
*No Tool Wear: Non-contact process avoids mechanical degradation.
Common Laser Types for Sheet Metal
Fiber Lasers: Best for thin to medium metals (up to 30mm), energy-efficient, high speed.
CO₂ Lasers: Suitable for thicker materials (up to 25mm) and non-metals.
Nd:YAG Lasers: Used for high-reflectivity metals like aluminum.
| Materials & Thickness Limits | |
| Material | Max Thickness (Fiber Laser) |
| Mild Steel | 20–25 mm |
| Stainless Steel | 15–20 mm |
| Aluminum | 12–15 mm |
| Copper/Brass | 8–10 mm |
| Cutting Parameters by Material | ||||
| Material | Power (W) | Speed (m/min) | Assist Gas | Pressure (Bar) |
| Mild Steel | 1000–6000 | 2–10 | O₂ (Oxidation) | 4–10 |
| Stainless | 1000–4000 | 1–6 | N₂ (Clean cut) | 8–16 |
| Aluminum | 2000–6000 | 1–4 | N₂ | 10–20 |
| Copper/Brass | 1500–4000 | 0.5–3 | N₂ | 10–15 |
| Standard Sheet Metal Materials for Laser Cutting | |||
| Material | Common Grades | Thickness Range (mm) | Key Properties |
| Mild Steel | AISI 1008, 1010, 1018 | 0.5 – 25 | Low cost, good weldability |
| Stainless Steel | 304, 316, 430 | 0.5 – 20 | Corrosion-resistant, smooth edges |
| Aluminum | 5052, 6061, 6082 | 0.5 – 15 | Lightweight, reflective (needs N₂) |
| Copper | C110, C101 (Electrolytic) | 0.5 – 10 | High conductivity, reflective |
| Brass | C260 (Cartridge Brass) | 0.5 – 8 | Decorative, requires N₂ assist gas |
| Galvanized Steel | DX51D, DX52D | 0.5 – 12 | Zinc-coated, emits toxic fumes |
|
Assemble & Packaging
1. Assembly Processing
A. Deburring & Edge Smoothing
Methods:
Vibratory Tumbling: For small parts in bulk.
Manual Grinding/Sanding: For precision edges.
Laser Deburring: High-precision edge cleaning.
Purpose: Remove sharp edges (burrs) for safety and fitment.
B. Forming & Bending
Press Brake Bending: CNC-controlled for accurate angles.
Bend Allowance Calculation: Compensates for material stretch.
Tool Selection: V-die width depends on material thickness.
Roll Forming: For curved parts ( cylinders).
| C. Joining Methods | |||
| Method | Best For | Pros | Cons |
| Welding | Structural joints (steel) | Strong, permanent | Heat distortion, HAZ |
| Riveting | Non-weldable metals (Al) | No heat, removable | Less aesthetic |
| Adhesives | Lightweight assemblies | No deformation, smooth finish | Lower strength |
| Fasteners | Serviceable parts | Easy disassembly | Adds weight |
D. Surface Finishing
Powder Coating: Durable, corrosion-resistant, color options.
Anodizing (Aluminum): Improves hardness & corrosion resistance.
Plating (Zinc, Nickel): Enhances conductivity & wear resistance.
Painting: For aesthetic or protective purposes.
E. Inspection & Quality Control
Dimensional Checks: Calipers, CMM (Coordinate Measuring Machine).
Weld Integrity: X-ray or ultrasonic testing (critical applications).
Surface Defects: Visual inspection for scratches/dents.
2. Packaging Methods for Sheet Metal Parts
A. Protective Packaging
Foam Inserts: Prevents scratches during transit.
Edge Guards: Cardboard/plastic protectors for sharp edges.
Anti-Corrosion Measures:
VCI (Vapor Corrosion Inhibitor) Paper: Releases anti-rust vapors.
Desiccant Packs: Absorbs moisture in sealed packages.
| B. Packing by Part Type | |
| Part Type | Packaging Method |
| Flat Parts | Stacked with separator sheets |
| Bent/Folded | Custom foam or molded trays |
| Small Components | Plastic bags (ziplock/bubble wrap) |
| Large Assemblies | Wooden crates with padding |
C. Shipping Considerations
Pallets: Standard 1200×800 mm (EU) or 48×40" (US).
Weight Distribution: Avoid overloading to prevent bending.
Labeling:
Fragile Stickers for delicate parts.
Part Numbers & QTY for easy identification.
| 3. Common Defects in Assembly & Packaging | ||
| Issue | Cause | Solution |
| Scratches/Dents | Poor handling | Use protective films/foam |
| Rust Formation | Humidity exposure | VCI paper + desiccants |
| Misaligned Parts | Incorrect fixturing | Check jigs before assembly |
| Bent Edges in Transit | Insufficient support | Reinforce packaging with foam |
4. Automation in Assembly & Packaging
Robotic Welding: For high-volume production.
Automated Conveyor Systems: Moves parts between stations.
Vision Inspection Systems: Detects assembly defects.
Final Checklist Before Shipment
*All parts deburred & cleaned
*Assembly meets tolerances
*Surface treatment applied (if needed)
*Packaging prevents damage
*Labels & documentation included
