Prevention is Better Than Cure, Even In the Mechanical World Most people would already know that LASER is an acronym of Light Amplification by Stimulated Emission of Radiation. However, not all of them would know its use. Lasers have a diverse range of usability. One of its uses is to cut through metal plates. Yes! A stimulated emission of radiation, which is light energy, is capable of melting metal.
Why do we need laser for metal cutting?
It cuts some of the metals and alloys like, mild steel, stainless steel, and aluminum plate swiftly. The cutting process on these materials is highly accurate. Moreover, the cut quality yield is also excellent. Another advantage is that laser cutting has a very small kerfs width and a minute heat effect zone. This opens a door for carving intricate geometrical shapes and small holes.
How it engages in cutting metal? In brief, laser beam is a column of high intensity light of a single wavelength. For a CO2 laser, the wavelength remains in the infrared part of the electromagnetic spectrum. The beam is of about 0.75 of an inch in diameter when it travels through the laser resonator. The resonator creates the beam. Number of bend mirrors along the machines beam path bounces the beam in different directions. The beam now concentrates while it flows through the nozzle. The ignited fire hits the plate through the nozzle bore to melt the metal. The instrument is under high tension while in operation and undergoes an extreme level of stress. This results in wear and tear of the components in use. To operate without fatigue, the laser consumables and spare parts need preventive maintenance and require an expert supervision. The feasibility and efficiency of the production solely lies on the shoulders of these components. For higher metal cutting efficiency, the laser consumables, which are in use, need to have these characteristics: • Highest Quality • Durability • Feasibility
• Easy Replacement Therefore, it is obvious that top quality machinery requires top quality consumables. However, another question is which are the most important consumables?
Here are the few consumables which need special care for the sophistication that you require your gun to be blazing to melt the metal.
Nozzles Nozzle is the part of a lasercutting device, which fires the intense laser beam on the material. A faulty nozzle would make it difficult to ponder the laser beam’s energy on the required spot. Characteristics of an efficient laser beam are: • Economically Viable • Chrome Plated
• Contact and noncontact height regulation system • Prevents buildup of slag
Mitsubishi Laser Consumables provide a unique onepiece nozzle design, which reduce nozzle catering and prevent buildup of slag.
Laser Mirrors Bend mirrors or laser mirrors are reflective coatings necessary for laser reflection. Characteristics of bend mirrors are: • OEM Certified • The hard
• Durable • Dielectric multilayer coating for ensuring high reflection • High damage threshold Generally, these mirrors are having an inclination of 45° against the beam direction. They are always under high stress as they constantly deflect the powerful laser beam and delivering it to the nozzle. They are the key factors in laser machine's productivity and performance. The OEM bend Mirrors can reflect precise beam quality, which provide consistent power to the cut and lets you achieve higher edge quality.
Break Away Bolts Break away bolts have special design and have a low break point at the head. This is to ensure minimum impact of damage and losses if any. These bolts break when unwanted pressure exerts on the laser machine. Break away bolts reduce costly repairs due to crashes.
Miscellaneous In addition to these consumables, few other components are also under the maintenance radar. These are: • Dust collector filters • The cooling system of the laser machine too requires water filter • Air Filter for the health and safety of the staff in the cutting environment • Insulators • Resonator Optics
Steve M Glassner is the General manager of Alternative Parts Inc, the leading manufacturer and distributor of machine parts for Amada, Trumpf and various other brand including Mitsubishi laser parts. Steve is a Machine Tools industry enthusiast and frequently writes about various aspects of the industry.