Fine Cutting with Solid-State Lasers
David Locke TRUMPF Laser Plymouth Twp., MI June 21, 2012
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Characteristics of Fine Cutting
Thinner materials
Smaller geometries
Sharper contours and features
Lower laser powers
Finer focusing
Modulation and pulsing
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Challenges of Fine Cutting
Motion system acceleration and deceleration
Controling laser power in sharp corners
Accomodating smaller focused beams
Assist gas delivery
Part holding
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Cutting thin sheet with 1 µm wavelength
source: Fraunhofer ILT, Aachen / Germany TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
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Cut quality – Roughness
Roughness Rz [µm]
100 Stainless steel 1.0 mm
80 Range 3 60 40
Range 2
Aluminum Mild steel Stainless steel Mild steel 1.0 mm
20 Range 1 0 0,8
1
1,2
1,5
2
2,5
3
Sheet thickness [mm] Aluminum 0.8 mm TRUMPF TruFiber sales Disk training Laser Applications
TLS 251bn--2012-03-12 TLD272so 20.07.2009
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Cutting with TruDisk 1000 24 Mild Steel (St37)
22
Stainless Steel (1.4301)
Cutting Speed in m/min
20
Aluminum (AlMg3)
18
Cutting Gas and Spot Size Adapted to Application Focusing Optics: HSL D50
16 14 12
TW562ho 11.12.2006
10 8 6 4 2 0 0
1
2
3
4
5
6
Material Thickness in mm TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
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Cutting of Stainless Steel with TruDisk 1000
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Cutting with Disklaser Production speed Cutting quality Free of burrs Cutting of free contours
Production speed [m/min] Schneidgeschwindigkeit [m/min]
30
25
Maximum Cutting Speed
Production Speed
20
2 mm*mrad.
single mode Source: IFSW Stuttgart
15
10
5
0 0
1
2
3
[mm] SheetBlechdicke thickness [mm] TRUMPF Disk Laser Applications
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5
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Cutting with TruFiber 200/300/400 120
Cutting Speed in m/min
TruFiber 400 TruFiber 300
100
TruFiber 200 Stainless Steel Dross Free 1D Fusion Cutting: Nitrogen Spot Size: div
80
60
40
TLS259kr 09.10.2009
20
0 0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
1,1
1,2
1,3
1,4
1,5
Material Thickness in mm TRUMPF TruFiber sales Disk training Laser Applications
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Cutting with TruFiber 400 – Different materials
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Cutting with TruFiber Good cut quality up to a sheet thickness of < 1.2 mm (stainless steel) Especially in thin sheets high cutting speeds are possible (v > 20 m/min) Big process windows in regard to focus position (in z) and travel speed Cutting kerf width typically < 100 µm
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Cutting – Stator and rotor sheets fc = 80 mm, f = 150 mm ITEC Gas N2, Nozzle 1.5 mm, 16 bar 0.2 mm - 100 W cw with 6 m/min 0.35 mm - 100 W cw with 6 m/min 0.5 mm - 200 W cw with 6 m/min Better quality with pulsing - 250 W, 0.4 ms, 2450 Hz with 6 m/min
Cutassist adapts laser power for small contours automatically TRUMPFsales TruFiber Disk training Laser Applications
TLD272so TLS 251bn--2012-03-12 20.07.2009
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Cutting – Electrical parts fc = 100 mm, f = 100 mm Gas O2, Nozzle 0.8 mm, 16 bar 0.3 mm Copper - 250 W, 0.062 ms @ 10 kHz with 0.8 m/min Video of copper cutting Top side
Bottom side
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Cutting – Baking tray fc = 100 mm, f = 100 mm Gas N2, Nozzle 1.2 mm, 20 bar 0.7 mm black steel - 300 W, 0.3 ms @ 1250 Hz with 4 m/min
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Cutting – Lead frame fc = 100 mm, f = 100 mm Gas O2, Nozzle 1.2 mm, 3 bar 0.4 mm copper - 250 W cw with 1 m/min
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Cutting video – Mobile phone housings CrNi 0.4 mm TruLaser Cell 3010 fc = 100 mm, f = 150 mm Gas N2, Nozzle 1.4 mm, ≤ 16 bar Big contours: 400 W cw with up to 16 m/min Fine contours: Modulated output according to laser technology table in TruLaser Cell 3010 TRUMPFsales TruFiber Disk training Laser Applications
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TruControl Module Cutassist Cutting of Corners and Small Contours
Properties of the Cutassist Cause of fault in small contours The input signal Eleven laser parameters Modulation and pulsing Database Examples
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Cutting without Module Cutassist When approaching corners, edges and reversal points of a contour to be cut, the velocity must be reduced, but the laser power stays constant A high distance energy causes an increased heat production and more molten material If the contours to be cut are located at a small distance from each other, the heat dissipation is blocked Results: - Melting loss on the edges - Big heat affected zone - Burrs TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
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Cutting with Module Cutassist Module Cutassist adapts the laser parameters to the reduced velocity when processing corners, edges or reversal points Cutting without Module Cutassist
The velocity signal from the CNC control is processed and transformed into a laser power default This will result in an optimum adaptation of the laser parameters (CW power and/or pulsed mode) Benefits: - Constant energy input per unit length - Optimum cutting quality - Minimum cutting time TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Cutting with Module Cutassist
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Module Cutassist - Operating mode Velocity signal
CNC www.itec-online.de
Laser power signal
TruControl
Laser source
Synchronity Signal of axis
Laser beam Cutting process
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TLS 251bn - 20.07.2009
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Module Cutassist - Adaption of laser parameters Velocity signal
1 Fixed CW power 2 Readjusted CW poser
Cutassist
0
4
vu
4 1
2
3
vu
4
3 Readjusted pulsed mode 4 Fixed pulsed mode
3
vm 2
v0
3
Laser power
vm
1 2
vprocess
v0 1
vprocess
v0
vm
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vu
0
vprocess TLS 251bn - 20.07.2009
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Module Cutassist - Laser parameters in detail Po
vprocess
Pmo
v0
Pmu P^m Fm
vm
Pu P^u Fu
vu
0
Range vprocess to v0 The laser uses default values Constant laser power
Range vm to vu The pulse power, pulse duration and frequency are constantly adapted to the speed The laser is working in the pulsed mode The pulse power, frequency and average power change
Range v0 to vm The laser power is continuously reduced The laser works in the CW mode
Range vu to 0 The parameters use the values programmed in vu The laser is working in the pulsed mode
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Cut editor and Cut database Cut editor
Cut database
In the cut editor, the parameter sets for the cutting of contours, small contours and punctures are created and saved
Optional part of Module Cutassist
The parameter sets can be called in the laser porgram
In this database are cutting parameters for all common materials in different thicknesses included by TRUMPF Cut database automatically creates all necessary technology parameters and Outputs the default values to set the machine
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Cut editor - User inferface 1
2
3
In the tab Piercing (3), the parameter set which produces the start hole for a cutting process is created. The tab Cutting (1) can be used to create a parameter set to cut a mixture of big and small geometries. In the bab Cutting of small contours (2) the laser works exclusively in the pulsed mode for an optimum cutting quality for very small geometries. Due to long pulse breaks, the material can cool down.
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
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Creation of cutting parameters without Cut database In the Cut editor the user assigns the necessary laser parameters to every velocity point on the cutting path and by doing this he creates his own material data bank. These default values must be observed: - Diameter and type of laser light cable (LLK) - Reproduction ratio of the focusing optics (focal lengths of collimation and cutting lens) - Cutting gas (type and pressure) - Cutting gas nozzle (diameter and distance to the workpiece) - Process velocity - Focal position
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Creation of cutting parameter sets with Cut database In the existing material data bank Cut database the user chooses type of material, thickness, collimation and lens in the Wizard
Further steps: - Check the settings on the machine and on the optics - Create laser program Processing can be started
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Module Cutassist - Example: quality improvement Material: Mild steel 2mm
Laser: TruDisk 1000
5mm
Velocity: 54 m/min
Without Module Cutassist TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
With Module Cutassist 30
How to get Module Cutassist Module Cutassist can be used with all CW-lasers using the TruControl 1000 control unit, e.g. TruDisk and TruFiber You can either order Module Cutassist directly with your new laser device or easily upgrade it at a later date
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TLS 251bn - 20.07.2009
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Example (1) medical tweezer; stainless steel 0.5 mm
No cutassist, only pulsing With cutassist, cw and pulsing
11 s 7,4 s
110 mm
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Example (2) latch of a cabinet; mild steel 2 mm
Pulsing with cutassist: corner intact CW with power control : corner damaged
10 mm
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Cutting with picosecond pulses Pulses short enough to vaporize material Free space beam guidance Scanner for fast beam steering
Cutting = repeated scribing (or scribe + break)
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Cutting with picosecond pulses Cutting of Nitinol Small cutting kerf (< 10-20 µm) Negligible HAZ High quality of cutting edge No electro polishing! High yield High productivity due to high average power Application: Cutting of Stents, endoscopes TruMicro TRUMPF 5000 Disk Laser © TRUMPF Applications - CONFIDENTIAL
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Cutting with picosecond pulses Cutting of Silicon Wafers Small cutting kerf (< 20 µm) Negligible HAZ High quality of cutting edge High productivity due to high average power Applications: Waferdicing
TruMicro TRUMPF 5000 Disk Laser © TRUMPF Applications - CONFIDENTIAL
TUS260sw TLS 251bn - 20.07.2009
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Cutting with picosecond pulses Cutting of Silicon Wafers Small cutting kerf (< 20 µm) Negligible HAZ High quality of cutting edge High productivity due to high average power Applications: Waferdicing
TruMicro TRUMPF 5000 Disk Laser © TRUMPF Applications - CONFIDENTIAL
TUS260sw TLS 251bn - 20.07.2009
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Cutting with picosecond pulses Scribing and cutting of Ceramics Small kerf width (< 20 µm) Negligible HAZ High quality of cutting edge High productivity due to high average power Applications: Scribing / cutting of ceramic PCBs
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Cutting with picosecond pulses Scribing and cutting of Ceramics Small kerf width (< 20 µm) Negligible HAZ High quality of cutting edge High productivity due to high average power Applications: Scribing / cutting of ceramic PCBs
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Cutting with picosecond pulses Scribing and cutting of thin glass Small kerf width (< 20 µm) Negligible HAZ High quality of cutting edge High productivity due to high average power Application: Scribing/cutting of thin glass for Flat-Panel-Displays
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Cutting with picosecond pulses Cutting of thicker glass
Glass Cutting
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Thank you for your attention!
David Locke TRUMPF Laser Technology Center 47711 Clipper Street Plymouth Twp., MI 48170
[email protected]
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
