Scientific laser cutting DFM assessment could help discover the best process parameters, precisely control the laser cutting cost, choose the most suitable assist gases for various materials, do away with the secondary deburring operation, and slash the processing energy usage and total gas costs by over 20%.
Comparison of three major assist gases
Gas dosing is one of the main elements of the laser cutting cost and necessitates accurate selection to keep costs under control. The DFM analysis service unit can identify the best gas option. With laser cutting DFM analysis plus working environments, the cost-effective choice is made and it is the fundamental rule of laser cutting gas matching.
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Assist Gas
Applicable Materials
Cutting Speed
Surface Quality
Gas Cost (USD/cubic meter)
Deburring Requirements
High-Pressure Nitrogen
Stainless Steel, Aluminum Alloy
Fast
No Oxidation, No Slag
2.5
Not Required
Low-Pressure Oxygen
Carbon Steel
Medium
Oxide Layer
0.3
Slight
Compressed Air
Ordinary Carbon Steel
Slow
Slight Slag
0.1
Required
Gas Parameter Optimization Strategy
Dedicated engineering support for laser cutting gives the possibility of the flexible modification of gas parameters for achieving a balance between quality and cost. Superior custom laser cutting service is the best way to ensure that you are not run through any unnecessary processing stages and this way get the maximum return on your laser cutting performance.
<オル>
The use of high-pressure nitrogen is recommended for the cuts performed on parts of very high aesthetical quality to have the cuts free of oxidation.
The internal structural components can be cut with low-pressure oxygen to enjoy the reduction of costs.
To continue the cost savings, for the parts with no time limitation, the use of compressed air cutting can be made.
Why Is Early Stage Layout Nesting Optimization Critical For Establishing a Competitive Custom Laser Cutting Service Quote?
Involving the source manufacturer early in the layout stage and jointly doing common-edge optimization has the potential of drastically reducing sheet metal waste not only by nearly 18% but also procurement is made easier and quicker in obtaining a cost-effective quote that can be mass producing custom laser cutting services.
Shared-Edge Cutting Brings Cost Benefits
Delivering high quality custom laser cutting service, the manufacturers give prominence to shared-edge process that can bring the reduction of wastage materials. Scientific nesting is very capable of bringing down laser cutting costs, making the process of laser cutting more cost effective, and can be very resourceful in enhancing laser cutting nesting efficiency.
Lessening kerf length to half, cutting down the consumption of gas and nozzle.
Lower the piercing numbers, this results in a shorter production time.
Better use of the material, helps in reducing the price of the material.
Utilization of Intelligent Nesting Software
Starting from laser cutting design assistance, different nesting plans can be developed to suit the part structures. Large volume intelligent nesting for custom laser cut parts production can elevate the efficiency of laser cutting batch production to a high extent.
Sharing of contours between pieces can be identified automatically by the software.
Through re-arranging and re-orienting parts layouts, material can be utilized more efficiently.
The best cutting path can be planned by the software to reduce the production time and because of this the idle time.
<ブロック引用>
Intelligent nesting and shared-edge optimization can significantly reduce sheet metal waste and processing time, which is the core of obtaining high-quality, low-cost custom parts. For bulk orders, submit drawings to obtain an accurate custom laser cutting service quote.
LS Manufacturing Helps New Energy Vehicle Companies Successfully Optimize High-Precision 316L Stainless Steel Battery Busbar Laser Cutting Design
Customer Challenges
The Tier 1 supplier of new energy vehicles was fabricating 2.0mm thick 316L stainless steel battery busbars. Initially, the hole-to-thickness ratio was as low as 0.75. With conventional machining, issues such as melting, taper, and micro-cracks would inevitably occur, which made the overall part yield very low, increased costs, and even delayed delivery.
LS 製造ソリューション
LS Manufacturing's engineering support team reached out to the client for an in-depth laser cutting DFM service right after 24 hours of receiving the customer's drawings. The first step was to use our own thermal flow simulation software (with a calculation accuracy of 0.02mm) that models the heat input. After the IATF 16949 process review, the team developed a structural optimization solution that laser cuts automotive part defects with high precision.
<オル>
The size and shape of the hole were changed: Initially, the hole was circular. Now it is a racetrack-shaped elongated hole. The kerf width was made to a safe hole-to-thickness ratio of 1.2.
A smooth corner radius of 0.5mm is introduced.
No residue in the micro-connection configuration.
In production, 1.8MPa high-pressure pure nitrogen gas is used plus segmented interpolation cutting paths to reduce local heat conduction to a minimum.
結果と値
After the parts were optimized, the surface roughness of the parts are well stabilized to meet the standards, hole diameter tolerance is maintained within 0.04mm, all defects are wiped out and the batch pass rate is about 99.8%. Besides that, the material layout efficiency is greatly enhanced and secondary processing is completely done away with. As a result, the unit price after laser cutting has been lowered by a remarkable 24.5%, and mass production has been achieved successfully.
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Professional laser cutting DFM service can efficiently solve the machining challenges of precision stainless steel parts, improve yield rates, reduce production costs.You can submit project requirements to customize exclusive process optimization solutions for new energy parts.
よくある質問
Q1: Why can't the minimum hole diameter in laser cutting drawings be less than the material thickness?
Laser perforation with high energy density will cause heat accumulation in small holes. If the hole diameter is smaller than the material thickness, there will be no enough space for slag removal, which will lead to molten slag bouncing and burning the base material. This causes a large hole taper and oxide layer that are impossible to pass the conventional go/no-go gauge precision check.
Q2: What is Common-line Cutting (CFM), and how does it help reduce my procurement costs?
CFM is a technique that combines the outlines of two adjacent parts so that they share a kerf. Two parts are formed in one laser cut that makes their edges resulting in significant cutting reductions and decrease of laser cutting energy consumption, gas consumption, and unit costs.
Q3: When customizing aluminum alloy laser-cut parts, how does the DFM specification avoid the problem of severe slag buildup at the cut?
Aluminum alloys have excellent thermal conductivity as well as high reflectance. During the DFM phase, it is specified that the process radius should be at least 0.5mm and 1.6MPa high-pressure pure nitrogen cutting. The high-pressure jet of air rapidly removes the molten aluminum slag, thereby preventing the occurrence of slag buildup defect at the cut surface from the root.
Q4: Why does the "corner burning" occurrence occur during machining of sharp corners of parts without DFM optimization?
In laser cutting, upon reaching one sharp corner, the speed decreases and the laser beam moves back. The problem arises because the surface for heat dissipation at the sharp corner is minimal which results in a large drop of heat locally. And this is where the material gets vaporized and melted very fast that pits are formed which in the end causes corner burning mostly and scrapping.
Q5: What level of flatness and tolerance does LS Manufacturing provide for thin-plate precision stainless steel parts?
Using the pre-diffusion heat sink design and distributed cutting path process, we achieve control of thin-plate parts linear tolerance within 0.05mm for 3mm parts and a stable overall flatness of 0.1mm is possible even without additional leveling processes.
Q6: Why does striving for a drop-free look in appearance cause an increase in unnecessary indirect manufacturing costs?
Cutting speed must be lowered, very pure and costly gases must be used or secondary grinding must be done to get zero dross. If the parts are hidden and are not involved in assembly, then it is over-processing and the price of laser cutting goes up greatly.
Q7: How do I know if my precision sheet metal drawings have had the most skilled professional process review before mass production?
We have over 15 years of experience as sheet metal engineers. After you upload the drawings (in DXF, STEP, DWG formats), we will issue a professional DFM report within 24 hours, completing a comprehensive process review and cost optimization guidance.
Q8: Will the heat-affected zone (HAZ) of laser cutting have an impact on fluctuating dimensions during bending or the electroplating treatment on secondary surface?
The heat-affected zone is a thin strip of material alteration. In case bending clearance is not adequately planned in DFM stage and material grain changes are not taken into account, subsequent bending operation should generate cracking and will also affect the smoothness of the electroplating surface treatment.
概要
Laser cutting is not just a simple cutting operation but a complex precision manufacturing process. Introducing professional laser cutting DFM service at the preliminary stages of a project really help to steer clear of processing defects like burnt corners, taper, and thin sheet warping. Besides, through the optimized layout and common-edge cutting production costs are cut down and performance of the product is not compromised. Besides, the transition from prototype to mass production will be made easy and quick.
Repeated design drawings and changes in process parameters always result in high processing costs and delivery delays. LS Manufacturing relies on mature experience in precision sheet metal manufacturing to provide professional and reliable process technology support for various commercial and civilian laser cutting projects.
You may upload 2D/3D drawings in DXF, STEP, or DWG formats our expert engineers are ready to give you a free, open, and tailor-made DFM assessing report within 24 hours plus a quote for laser cutting mass production at a reasonable price.
[🌟Upload drawings now for a free DFM process assessment and accurate commercial quote]
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LS 製造チーム
LS Manufacturing は業界をリードする企業です。カスタム製造ソリューションに焦点を当てます。 We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. Metal stamping,and other one-stop manufacturing services. Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified.当社は、世界 150 か国以上のお客様に、迅速、効率的、高品質の製造ソリューションを提供しています。少量生産でも大規模なカスタマイズでも、24時間以内の最速納期でお客様のニーズにお応えします。 LSマニュファクチャリングを選択します。 This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com.
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