Patent Application
20230219174
The invention relates to a method for laser fusion cutting a workpiece, in particular a plate-shaped workpiece, wherein a laser beam and a cutting gas, in particular nitrogen, at a cutting gas pressure are directed at the workpiece surface by a convergent cutting nozzle, and wherein the laser power is at least 6 kW.
In the case of laser fusion cutting, the material of the workpiece is melted to form a kerf and is evacuated in liquid form from the kerf by means of a cutting gas. The workpiece may be a sheet, in particular a metal and/or electrically conductive sheet. During laser fusion cutting, the laser beam and the workpiece are moved relative to one another along a (generally variable) cutting direction, wherein the kerf in the workpiece is formed counter to the cutting direction.
The properties of the cutting gas jet emerging from the nozzle can influence the quality of the kerf. It is therefore known to influence the cutting gas jet by way of the shape of the nozzle and the cutting gas pressure.
Published, non-prosecuted German patent application DE 102016215019 A1, corresponding to U.S. Pat. No. 10,675,708, discloses a fusion cutting method with a convergent nozzle, in the case of which method the cutting gas has a cutting gas pressure of at most 10 bar, the nozzle has an opening diameter of at least 7 mm, and in the case of which method the distance between the nozzle end face and the workpiece surface is 0.5 mm, in order to minimize the consumption of cutting gas. This method achieves high cutting speed along with good quality of the cutting edges. However, this cutting process is very susceptible to the nozzle colliding with tilted workpiece parts, in particular owing to the small distance between the nozzle and the workpiece surface.
International patent disclosure WO 2018068853 A1, corresponding to U.S. Pat. No. 11,458,574, describes a laser cutting method with a Laval nozzle, in the case of which method workpieces with a thickness of 1 to 4 mm are cut at a cutting gas pressure of between 8 and 23 bar and a distance between the nozzle and the workpiece surface of between 3 and 6 mm. Owing to the large dimensions of the Laval nozzle, this cutting process also runs an increased risk of collision.
An object of the invention is to propose a laser fusion cutting method that enables high productivity along with reduced risk of collision, i.e. higher process reliability.
This object is achieved according to the invention by a method according to the independent patent claim.
According to the invention, the cutting nozzle has a nozzle end face on the workpiece side, the distance A between the nozzle end face and the workpiece surface during the cutting operation, preferably throughout the cutting process (that is to say even during phases in which the laser is switched off, for example in the course of an on-the-fly puncturing operation) is 2 to 8 mm, in particular has a value between 4 mm and 8 mm. Further, according to one example, the distance A between the nozzle end face and the workpiece surface can be between 3 mm and 4 mm. Furthermore, according to the invention the cutting nozzle has a nozzle channel with a diameter dD at the nozzle end face on the workpiece side of 1.5 to 4 mm, in particular 2 to 3.3 mm, preferably 2 to 2.7 mm or 3 to 3.3 mm. The nozzle end face is that end face of the nozzle that is directed towards the workpiece during the cutting process. According to the invention, a cutting gas pressure before emergence from the cutting nozzle of 15 to 30 bar is used. For example, the cutting gas pressure before emergence from the cutting nozzle can be between 22 bar and 24 bar.
In the case of the method according to the invention, a convergent nozzle, that is to say a nozzle having a nozzle channel that tapers in the flow direction, is used. The outlet cross section (nozzle diameter at the nozzle end face on the workpiece side) is therefore at the same time also the smallest cross section of the nozzle channel. Owing to the small nozzle channel cross section and the shape of the nozzle channel, it is possible to use a compact nozzle for the method according to the invention, this in turn resulting in a small disrupting contour and thus a reduced risk of collision.
At the same time, according to the invention the process distance (distance between the nozzle end face on the workpiece side and the workpiece surface) is selected as relatively large (2-8 mm). This further reduces the risk of collision. In addition, it is ensured that the kerf is sufficiently covered by gas in spite of the small cross section of the nozzle channel.
The process distance according to the invention is compensated by the use of a correspondingly large cutting gas pressure (15 to 30 bar).
The overall result of the method according to the invention is a very small disrupting contour of the cutting nozzle and a small risk of collision, so that the process reliability is increased. The method according to the invention makes it possible to carry out a fusion cutting method at high cutting speeds (advancement speed of the cutting nozzle relative to the workpiece during the cutting operation), even in the case of large workpieces.
In a preferred variant, the distance between the nozzle end face and the workpiece surface is maintained throughout the cutting process. Adjustment of the distance during the cutting process can therefore be dispensed with, this further increasing the productivity of the overall process.
In a special variant of the method according to the invention, the cutting nozzle used is a single-channel nozzle or an annular die. This makes it possible to reduce the disrupting contour and the consumption of gas.
Preferably, the cutting gas pressure before emergence from the cutting nozzle is more than 18 bar, in particular at least 20 bar. In a special variant, the cutting gas pressure is at least 24 bar.
In a particularly preferred variant, the cutting nozzle is moved relative to the workpiece at least at times at a cutting speed of at least 60 m/min. In this respect, the cutting speed is denoted by the maximum advancement speed during the cutting operation (that is to say with the laser beam directed at the workpiece).
In a special variant, the focal position of the laser is selected such that it lies on the workpiece surface or in the workpiece half facing towards the cutting nozzle, in particular lies between 0.2 mm-1.5 mm below the top side of the sheet. The highest cutting speed can be reached in this focal position range.
The laser power during the cutting operation is preferably at least 10 kW. Owing to the high laser power used in the method according to the invention, it is possible to process thick workpieces. The method according to the invention can thus particularly advantageously be carried out on workpieces with a workpiece thickness D of at least 4 mm.
A particularly preferred variant of the method according to the invention provides that the laser beam punctures the workpiece surface at least at one puncture point while the cutting nozzle is being moved relative to the workpiece (on-the-fly puncturing operation). Such a process variant is primarily used whenever many small workpiece parts that are arranged in a line and have straight contour portions are to be cut. In the process, a laser cutting head with the cutting nozzle is moved linearly over the workpiece (or vice versa), and the laser beam (with cutting parameters) is switched on and off so that the puncturing operation takes place during the relative movement between the cutting nozzle and the workpiece (that is to say “on-the-fly”).
In the case of workpieces with a thickness of more than 4 mm, however, even at a laser power between 10 and 20 kW, the on-the-fly puncturing operation is not possible with good quality, since a clean puncture and start of the cut cannot be achieved at the desired cutting speeds. This problem can be solved by reducing the advancement speed at the puncture point, given otherwise unchanged process parameters. A special variant of the method according to the invention therefore provides that the advancement speed is reduced to a puncture speed, preferably by 10%-90% of the cutting speed, at the puncture point.
Preferably, the advancement speed is reduced to the puncture speed over a displacement distance of less than 2 mm, preferably less than 0.5 mm, in such a way that the puncture speed is reached at the puncture point. Reducing the advancement speed is thus commenced at most 2 mm upstream of the puncture point (in the advancement direction). In this way, it is ensured that, on the one hand, the speed is reduced with viable acceleration, and, on the other hand, the necessarily acceptable loss of time is not excessive. The advancement speed is reduced with the laser switched off.
Preferably, after the laser beam punctures the workpiece surface, the puncture speed is maintained for a few milliseconds and then the advancement speed is increased back up to the cutting speed.
Further advantages of the invention are evident from the description and the drawing. Similarly, according to the invention, the features mentioned above and those still to be further presented can be used in each case individually or together in any desired combinations. The embodiments shown and described should not be understood as an exhaustive enumeration, but rather are of an exemplary character for outlining the invention.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a laser cutting method, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
In the following description of the figures, identical reference signs are used for identical or functionally identical components.
Referring now to the figures of the drawings in detail and first, particularly to
According to the invention, a distance A between the nozzle end face 8 on the workpiece side and the workpiece surface 9 facing towards the cutting nozzle 1 is at least 2 mm, preferably at least 4 mm, in particular up to 8 mm. According to the invention, a focal position F of the laser beam 3 in the beam direction 6 is located within the thickness D of the workpiece 2, in the upper half of the workpiece 2 that faces towards the cutting nozzle 1 or on the workpiece surface 9 (the latter not being shown). Expressed differently, the focal position F of the laser beam 3 in the beam direction 6 is located in the workpiece 2 at a depth that is less than half D/2 of the thickness D of the workpiece 2.
The cutting nozzle 1 is moved over the workpiece 2 at a cutting speed in a cutting direction 7, which corresponds to the X direction of the XYZ coordinate system, in order to produce a kerf 4 in the workpiece 2.
When this operation is to be carried out on-the-fly, that is to say without stopping the cutting nozzle 1 at the puncture point 10, in the case of thick workpieces 2 it is advantageous to reduce the advancement speed of the cutting nozzle 1 upstream of the puncture point 10 (in the cutting direction). To that end, a laser cutting head with the cutting nozzle 1 is continuously moved linearly over the workpiece 2, wherein the advancement speed is reduced upstream of the puncture points 10 and increased back up again downstream of the puncture points 10.
The laser cutting machine 20 comprises, for example, a solid-state laser or a diode laser as laser beam generator 21. The laser cutting machine 20 further has a displaceable (laser) cutting head 22, together with which the cutting nozzle 1 is moved, and a workpiece rest 23, on which the workpiece 2 is arranged. The laser beam 3 which is guided from the laser beam generator 21 to the cutting head 22 is generated in the laser beam generator 21. The laser beam 3 is directed at the workpiece 2 by means of a focusing optical unit arranged in the cutting head 22.
Moreover, the laser cutting machine 20 is supplied with cutting gas 24, in this instance nitrogen. To carry out the laser fusion cutting method according to the invention that is described above, nitrogen as cutting gas 24 is supplied to the cutting nozzle 1 of the cutting head 22, to be precise at an overpressure of approximately 15-30 bar (before the emergence of the cutting gas 24 from the cutting nozzle 1).
Further, the laser cutting machine 20 contains a machine controller 25 which is programmed to move the cutting head 22, together with its cutting nozzle 1, relative to the stationary workpiece 2 in accordance with a cutting contour. The machine controller 25 also controls the power of the laser beam generator 21, which is more than 6 kW and in particular is more than 10 kW in the case of the fusion cutting process described above. In this way, for example, given a workpiece thickness of 1.5 mm at 6 kW, a cutting speed (advancement) of 60 m/min or even higher can be reached, with the cutting speed increasing as the laser power increases.
The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention.
1 Cutting nozzle
3 Laser beam
5 Nozzle channel
6 Beam direction of the laser beam
7 Cutting direction
8 Nozzle end face
9 Workpiece surface
10 Puncture points
11 Contour portion
20 Laser cutting machine
21 Laser beam generator
22 Cutting head
23 Workpiece rest
25 Machine controller
F Focal position
D Workpiece thickness
dF Laser beam diameter
dD Nozzle channel diameter
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2020 212 088.9 | Sep 2020 | DE | national |
This application is a continuation, under 35 U.S.C. § 120, of copending International Patent Application PCT/EP2021/075299, filed Sep. 15, 2021, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German Patent Application DE 10 2020 212 088.9, filed Sep. 25, 2020; the prior applications are herewith incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2021/075299 | Sep 2021 | US |
| Child | 18187821 | US |
