Sheet metal cutting with fiber

lasers

About Bystronic
Introduction
Results and Discussion
Summary

Andreas Ldi and Stefan Wittwer

Bystronic Laser AG

B t
Bystronic:
i Key
K
Figures
Fi
Established in 1985
Field of activity: Sheet
Metal Processing
Systems
Headq
Headquarters:
arters
Niedernz (CH)
Si
Since 1994 partt off the
th
Conzzeta Group
Sales 500 mio. (2008)
Employees 1627
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 2

B t
Bystronic:
i Core
C
Activities
A ti iti
Laser
L
Cutting

Waterjet
W
t j t
Cutting

Bending

Process chain:
cutting - bending
All from a single source
For all flat materials and
all shapes
Handling &
Automation

Software &
Control

Services &
Support

Automation of the
complete mate
materials
ials and
data flow
For increased productivity
and cost efficiency
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 3

I t d ti /M ti ti
Introduction/Motivation
Wish list for a laser cutting system
CO2

Cost effecti e
Cost-effective

Reliable autonomous operation

Energy-efficient
Energy
efficient

Compact layout

Simple operation

Little maintenance

Continuous high output

Good cut quality

Source: PM By
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 4

fiber

O ti configurations
Optic
fi
ti
dFocus=(fF/fC)dFiber

fC

dFiber
several optic configurations
450

fC [mm]

focal diameter [u
um]

400

fF

dFocus
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 5

150 m

350
300

100 m

250
200

50 m

150
100
50
100

120

140

160

180

200

focal
focal length
length f[mm]
F [mm]

220

69
75
100

C tti
Cutting
results
lt 2005:
2005 Aluminum
Al
i
Aluminium

Speed
> 4mm similar to 2 kW CO2

18000
IPG 2 kW
Fiber
Bylaser2200
y2 2
CO
CO2
2 kW
kW

14000

< 4mm faster than 5 kW CO2

Bylaser4000
CO
CO2
4 kW
kW
2 4

Cuttin
ng speed

Vorschub (mm/min)

16000

12000

Bylaser4400
CO
CO2
4.4 kW
kW
2 4.4

10000

Bylaser5200
CO2
CO
5 kW
kW
2 5

8000

Q lit
Quality

6000

Similar to CO2.

4000
2000
0
1

1.5

Dicke (mm) [mm]

Thickness

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 6

C tti
Cutting
results
lt 2005:
2005 Steel
St l (O2)
Speed

Baustahl

10000

Fiber
IPG 2 kW
CO
Bylaser2200
2 2 kW

9000

CO
Bylaser4000
2 4 kW

< 5mm similar to 5 kW CO2

CO
Bylaser4400
2 4.4 kW
CO
Bylaser5200
2 5 kW

7000

Cutting
g speed

Vorschub
b (mm/min)

8000

> 5mm similar to 2 kW CO2

6000
5000

Quality

4000

< 6mm very good

3000

> 6mm good

2000
1000
0
1

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 7

Thickness
[mm]
Dicke (mm)

10

12

15

20

C tti
Cutting
results
lt 2005:
2005 Stainless
St i l
steel
t l
Edelstahl

Speed

13000

Fiber 2 kW
Faserlaser
IPG

12000

CO2 2 kW
Bylaser2200

11000

CO2 4 kW
Bylaser4000

> 4mm similar to 2 kW CO2

< 4mm faster than 5 kW CO2

COl 2 4.4
4 4400
4 kW
Bylaser4400
B

10000

Cuttin
ng speed

Vorschub
b (mm/min)

14000

Bylaser5200
CO2 5 kW

9000
8000
7000

Quality

6000
5000

Rather rough cut,

4000

worse than CO2

3000
2000
1000
0
1

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 8

1.5

Thickness
Dicke (mm) [mm]

C tti
Cutting
results
lt 2005:
2005 Stainless
St i l
steel
t l

fiber

Rz<10 m

CO2

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 9

fiber laser: 4mm stainless steel

rough cut; Rz ~ 30 m (lower region)

CO2 laser: 4mm stainless steel

smooth surface with Rz < 10 m

C tti
Cutting
possibilities:
ibiliti
Fiber
Fib vs. CO2

Fiber laser cuts faster

N2

O2

Comparable cut quality of

fiber- and CO2-laser

G d cutt quality
Good
lit only
l with
ith
CO2-laser

Comparable cutting speed of CO2 and fiber laser

Comparable cutting quality of CO2 and fiber laser

1mm - 5mm
2009 Bystronic
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26.11.2009, Folie 10

5mm - 20mm

comparison with equal optical power / Source: Optech Consulting, 2009

Sit ti
Situation
today
t d
Today, most fiber laser cutting machines are
Today
used for thin sheets.
-ByVention Fiber 2 kW
2007 Munich
(presented on Laser 2007 WORLD
OF PHOTONICS, Munich)

-several fiber laser cutting machines have been

presented on Euroblech 08
08, Hannover
Hannover.
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 11

an approach
h to
t improve
i
cutt quality
lit

Absorption [a
a.U.]

Laser beam

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 12

Angle of incidence v [deg]

A l off incidence
Angle
i id

Laser beam

Laser beam

Dsheet

Dsheet
-1(
tan
ta
)
vmin
i =
DLaser beam
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 13

Laser beam

Absorption [a.U.]]

A l off incidence:
Angle
i id
sheet
h t thi
thickness
k

Angle of incidence v [deg]

Dsheet
-1(
tan
ta
)
vmin
i =
DLaser beam
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 14

A l off iincidence:
Angle
id
b
beam tilti
tilting
Dsheet=4 mm,
DLaser=0.3
mm
Blechdicke=4mm,
Durchmesser
Strahl=0.4
mm

85

84.9

84 8
84.8

Angle
v [d
deg]
Winkel
w

84.7

84.6

84.5

84.4

84.3

84.2
70

75

80

85

90
Winkel a

95

Angle a [deg]

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 15

100

Absorp
ption [a.U
U.]

A l off incidence:
Angle
i id
elongated
l
t d beam
b

Angle of incidence v [deg]

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 16

Dsheet
vmin= tan-1(D

Laser beam

A l off iincidence:
Angle
id
ffocall position
iti

Absorp
ption [a.U
U.]

Extreme focal position

p

Angle of incidence v [deg]

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 17

C t quality
Cut
lit improvements
i
t

Standard cut (@2kW)

47.3 m
70.2 m

1.43
301; D=6
6mm

26.1 m

Cut with extreme focal position (@2kW)

Reduced burrs
Reduced roughness
2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 18

16.9 m
21.7 m
28.0 m

- 1m lasers have inherent disadvantage

concerning fusion cutting of thick sheet metals
(and v.v. concerning thin sheet metals)

- Improvements of cut quality can be achieved

by improved incoupling of laser radiation

Absorption [a.U.]

Summary

Angle of incidence v [deg]

Thank you for your attention

2009 Bystronic
Swisslaser.net Workshop Burgdorf 2009
26.11.2009, Folie 19