Cutting metal is the most common requirement in the field of metal processing. With the continuous advancement of laser technology and the increasing demand from companies for high-quality and efficient cutting of workpieces, more and more businesses are abandoning traditional blade cutting in favor of laser cutting. Even though the cost of a laser cutting machine has been cheaper a lot compared few years ago, it still costs more than $10000 if you need a high-power output industrial metal laser cutting machine.
So it’s worth spending some time to fully figure out the acknowledgment about laser cutting machines. This article will introduce how to select the most suitable laser-cutting machine for your business and how it works. We will stand the view that a manufacturer of metal fiber laser cutting machine to provide you some points.
1. What is the laser?
Laser actually is a shortage from Light Amplification by Simulated Emission of Radiation, The basis of lasers stems from a theory developed by Albert Einstein.
In 1917, the great Albert Einstein came up with a whole new theory of technology: light interacting with matter.
As we all know, matter consists of atomic molecules.
Atomic molecules also carry electrons. These particles all have different energy states (energy levels).
This theory says that there are different numbers of particles (electrons) in the atoms that make up matter, and they are all at different energy levels. Some have high energy levels and some have low energy levels.
The particles in the higher energy levels are excited by some kind of photon from the outside world and will jump from the higher energy level (E2) to the lower energy level (E1). This will emit light with an energy of ΔE, which happens to have the same frequency and direction as the light that excited it. In some states, we can also excite a strong light by a weak light. This phenomenon is called “light amplification by stimulated radiation”, or laser for short.
The energy of a photon is calculated using E=hv, where h is Planck’s constant and v is the frequency.
It follows that the higher the frequency, the higher the energy.
2. What can lasers do?
Lasers are capable of converting light energy into heat energy.
1-20W lasers are generally widely used in microelectronics, and when the power reaches 30 to 100W it can be applied to surgical laser procedures, such as whitening.
When the laser power reaches 100 to 3000W, it can be used in industrial metal cutting.
3. Fiber laser cutting machine Vs CO2 laser cutting machine
The mechanisms used to create and focus the laser are the main differences between CO2 and fiber lasers. The CO2 and fiber lasers also have different wavelengths, which makes them suitable for different materials.
Mechanisms & Mediums
Fiber lasers use a crystalline solid as a fiber, and this is guided into the machine’s cutting head through a transport fiber.
CO2 lasers are a kind of gas excitation devices. It uses gases such as carbon dioxide(CO2), nitrogen(N2), helium(He), and sometimes xenon or hydrogen to produce the laser beam in an energy sequence.
Wavelength
They have different wavelengths, The wavelength of the fiber laser (1.06 μm) is shorter than the wavelength of CO2 (10.6 μm).
1.06μm wavelength can be fully absorbed by metal, even reflective metals.
The wavelength of C02(10.6 μm) is strongly absorbed by organic materials such as wood, plastic, fabric, and leather.
Cost
Even though the initial investment of a CO2 laser cutting machine is cheaper than purchasing a metal fiber laser cutting machine, the maintenance cost of CO2 is expensive. Because of this, the photoelectric conversion efficiency of a fiber laser is about 30%. The photoelectric conversion efficiency of the CO2 laser is 6 ~ 10%. In addition, the fiber laser source has no vulnerable parts, and maintenance costs are typically low.
Speed
The speed for cutting metal, the fiber laser cutting machine is faster than CO2 by nearly 2 or 4 times.
So if you purchase a laser cutting machine for metal sheet cutting such as carbon steel, Stainless steel, or Titanium cutter then it’s your best choice, moreover especially if you want to cut copper and brass.
4.How to produce a fiber laser cutting machine?
As a professional manufacturer of fiber laser cutting machines, we will produce through these steps as below:
1. Frame Construction
Building a machine frame:
Use aluminum profiles or materials such as steel to build the frame. Ensure that all parts are perpendicular and parallel.
Reserve space for the moving system, cutting table, and other parts.
Assembly of the gantry system or motion system:
Install the Y-axis and motion system on the frame using either a screwdriver or a belt driver.
Adjust the belt tension or screw nut to ensure a steady, stutter-free operation.
Installation of the up-and-down structure for the Laser Head; using ball screws or lead screws to ensure moving accuracy.
Installing the cutting table:
To support the workpiece, a honeycomb cutting bed should be installed on the bottom of the frame. The laser head must be positioned vertically and level with the bed. Its height must also be adjustable.
2. Laser and Optics Setup
Mounting laser source:
Fix the CO2 Laser Tubes and Diode Laser Module on the frame. Heat dissipation, shockproofing, and durability are important.
Connect the high-pressure sources of energy or driving sources, and make sure that all wires are correctly connected and insulated.
Aligning lenses and mirrors:
Mirrors with reflective surfaces should be placed at the laser’s output. They should be adjusted so that the laser beam can shoot straight up.
The cutting head is equipped with focus lenses, and it should be adjusted so that the laser beam is focused on the surface of the material.
The light paths can be optimized by continuously fine-tuning to improve the cutting performance.
Connecting the water cooling system (if applicable)
Equip CO2 Laser Tubes with a cooling system that is connected to both the return and inlet water pipes.
To ensure a smooth and sound circulation of cooling fluid without leaks, check that the waterway is closed and tight.
3. Electronics and Wiring
wire motors with limit switches:
To ensure correct connections, the motors are connected on the X-Y-Z axes.
To prevent laser head collisions, install limit switches on both ends of the axis and connect them to the controller board.
Connecting to the Laser Control Board
Select the correct connection method for the laser control board and power supply.
To avoid burning other components, check the connection of the wires to ensure that they are correctly transmitting signals.
Set up the emergency stop and power supply:
Connect the laser, the control board, and the motor to the power source.
Install an emergency stop switch to ensure safety and cut off the energy source.
4. Software Configuration
Installation and configuration of control software
Select the appropriate control software for your control board.
Set laser power, cutting parameters, and speed according to the settings of the software.
Calibrate the laser cutter
To ensure precise focusing, adjust the relative position of the laser head to the cutting bed.
Use the calibration program to test the repeatability and accuracy of the movement in X,Y, and Z directions.
Running Test Cuts
Fix the test materials like wood or acrylic to the cutting bed.
Send a simple pattern to your laser cutter for testing. Circular and square patterns are both acceptable.
Optimize cutting parameters after evaluating cutting results.
5.What are the things to consider when choosing the right laser cutter?
The right laser technology depends on the needs and applications of your business. Consider these important factors:
| Factor | Key Points |
| Material Compatibility | Determine the primary materials you will use. Ensure the absorption spectrum matches the selected laser type to avoid complications, slower processing, and higher energy consumption. |
| Work Area | Consider the size of the workpieces you expect to cut. Select a machine with a large enough work area for your jobs. You may need two machines to cover a range of job sizes. |
| Laser Power | Laser power affects cutting speed and thickness capacity. Higher laser power allows for faster cutting of thicker materials but increases equipment costs. Balance power with workload. |
| Beam Quality/Precision | Pay attention to the beam quality of the machines. Fiber lasers offer better beam quality than CO2 lasers, resulting in smoother engraving and finer cuts. |
| Speed/Throughput | Consider production volume and turnaround time. Fiber lasers are faster than CO2 lasers for metal cutting, which is critical for industrial-scale operations but increases CAPEX. |
| Software/Automation | Evaluate features that enhance productivity and ease of use. Automated options and user-friendly software reduce setup and operation time. Advanced nesting software optimizes material use. |
| Maintenance Reliability | Understand the maintenance requirements. Solid-state lasers (e.g., fiber, direct diode) have fewer parts, are user-serviceable, and have higher uptime compared to CO2 lasers. |
| Extraction and Cooling | Ensure the machine has proper exhaust and cooling systems for safe and efficient operation. Proper equipment is needed to remove debris and fumes during engraving or cutting. |
| Gas Assist | Consider the type of gas assist required. Look for machines with lower gas consumption. Better beam quality or finer cutting reduces melt/debris and gas usage |
| Support | Evaluate the technical support and service provided. Ensure reliable support, including training, troubleshooting, and spare parts availability. Lack of support can become a burden. |
| Budget | Establish your budget for the laser cutter. Consider not only the initial cost but also ongoing costs like consumables, maintenance, and power. Automation can reduce long-term labor costs. |
Conclusion
Choosing the right metal fiber laser cutting machine requires careful consideration of various factors to ensure it meets your specific needs. From material compatibility and work area size to laser power and beam quality, each element plays a crucial role in the overall performance and cost-effectiveness of the machine. Additionally, aspects like speed, software automation, maintenance, and support services are vital for optimizing productivity and minimizing downtime. By thoroughly evaluating these criteria, you can select a laser cutter that not only enhances your operational efficiency but also provides long-term value for your investment.
