Cutting - Trumpf

Fine Cutting with Solid-State Lasers
David Locke
TRUMPF Laser
Plymouth Twp., MI
June 21, 2012
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Characteristics of Fine Cutting

Thinner materials

Smaller geometries

Sharper contours and features

Lower laser powers

Finer focusing

Modulation and pulsing
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Challenges of Fine Cutting

Motion system acceleration and deceleration

Controling laser power in sharp corners

Accomodating smaller focused beams

Assist gas delivery

Part holding
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Cutting thin sheet with 1 µm wavelength
source: Fraunhofer ILT, Aachen / Germany
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Cut quality – Roughness
Roughness Rz [µm]
100
Stainless steel 1.0 mm
80
Range 3
60
40
Range 2
Aluminum
Mild steel
Stainless steel
Mild steel 1.0 mm
20
Range 1
0
0,8
1
1,2
1,5
2
2,5
3
Sheet thickness [mm]
Aluminum 0.8 mm
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Cutting with TruDisk 1000
24
Mild Steel (St37)
22
Stainless Steel (1.4301)
Cutting Speed in m/min
20
Aluminum (AlMg3)
18
Cutting Gas and Spot Size
Adapted to Application
Focusing Optics: HSL D50
16
14
12
TW562ho
11.12.2006
10
8
6
4
2
0
0
1
2
3
4
5
6
Material Thickness in mm
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TLS 251bn - 20.07.2009
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Cutting of Stainless Steel with TruDisk 1000
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Cutting with Disklaser
Production speed
 Cutting quality
 Free of burrs
 Cutting of free contours
Production speed [m/min]
Schneidgeschwindigkeit
[m/min]
30
25
Maximum Cutting Speed
Production Speed
20
2 mm*mrad.
single mode
Source: IFSW Stuttgart
15
10
5
0
0
1
2
3
[mm]
SheetBlechdicke
thickness [mm]
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TLS 251bn - 20.07.2009
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5
back
8
Cutting with TruFiber 200/300/400
120
Cutting Speed in m/min
TruFiber 400
TruFiber 300
100
TruFiber 200
Stainless Steel
Dross Free
1D
Fusion Cutting: Nitrogen
Spot Size: div
80
60
40
TLS259kr
09.10.2009
20
0
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
1,1
1,2
1,3
1,4
1,5
Material Thickness in mm
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Cutting with TruFiber 400 – Different materials
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Cutting with TruFiber
 Good cut quality up to a sheet thickness of < 1.2 mm (stainless steel)
 Especially in thin sheets high cutting speeds are possible (v > 20 m/min)
 Big process windows in regard to focus position (in z) and travel speed
 Cutting kerf width typically < 100 µm
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Cutting – Stator and rotor sheets
 fc = 80 mm, f = 150 mm
 ITEC
 Gas N2, Nozzle 1.5 mm, 16 bar
 0.2 mm
- 100 W cw with 6 m/min
 0.35 mm
- 100 W cw with 6 m/min
 0.5 mm
- 200 W cw with 6 m/min
Better quality with pulsing
- 250 W, 0.4 ms, 2450 Hz with 6 m/min
 Cutassist adapts laser power for small contours automatically
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Cutting – Electrical parts
 fc = 100 mm, f = 100 mm
 Gas O2, Nozzle 0.8 mm, 16 bar
 0.3 mm Copper
- 250 W, 0.062 ms @ 10 kHz
with 0.8 m/min
Video of copper cutting
Top side
Bottom side
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Cutting – Baking tray
 fc = 100 mm, f = 100 mm
 Gas N2, Nozzle 1.2 mm, 20 bar
 0.7 mm black steel
- 300 W, 0.3 ms @ 1250 Hz
with 4 m/min
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Cutting – Lead frame
 fc = 100 mm, f = 100 mm
 Gas O2, Nozzle 1.2 mm, 3 bar
 0.4 mm copper
- 250 W cw
with 1 m/min
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Cutting video – Mobile phone housings
 CrNi 0.4 mm
 TruLaser Cell 3010
fc = 100 mm, f = 150 mm
Gas N2, Nozzle 1.4 mm,
≤ 16 bar
 Big contours:
400 W cw with
up to 16 m/min
 Fine contours:
Modulated output
according to laser
technology table in
TruLaser Cell 3010
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TruControl Module Cutassist
Cutting of Corners and Small Contours







Properties of the Cutassist
Cause of fault in small contours
The input signal
Eleven laser parameters
Modulation and pulsing
Database
Examples
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Cutting without Module Cutassist
 When approaching corners, edges and reversal
points of a contour to be cut, the velocity must
be reduced, but the laser power stays constant
 A high distance energy causes an increased
heat production and more molten material
 If the contours to be cut are located at a small
distance from each other, the heat dissipation is
blocked
 Results:
- Melting loss on the edges
- Big heat affected zone
- Burrs
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TLS 251bn - 20.07.2009
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Cutting with Module Cutassist
 Module Cutassist adapts the laser parameters to
the reduced velocity when processing corners,
edges or reversal points
Cutting without Module Cutassist
 The velocity signal from the CNC control is
processed and transformed into a laser power
default
 This will result in an optimum adaptation of the
laser parameters (CW power and/or pulsed mode)
 Benefits:
- Constant energy input per unit length
- Optimum cutting quality
- Minimum cutting time
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
Cutting with Module Cutassist
21
Module Cutassist - Operating mode
Velocity signal
CNC
www.itec-online.de
Laser power signal
TruControl
Laser source
Synchronity
Signal of axis
Laser beam
Cutting process
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TLS 251bn - 20.07.2009
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Module Cutassist - Adaption of laser parameters
Velocity signal
1 Fixed CW power
2 Readjusted CW poser
Cutassist
0
4
vu
4
1
2
3
vu
4
3 Readjusted pulsed mode
4 Fixed pulsed mode
3
vm
2
v0
3
Laser power
vm
1
2
vprocess
v0
1
vprocess
v0
vm
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vu
0
vprocess
TLS 251bn - 20.07.2009
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Module Cutassist - Laser parameters in detail
Po
vprocess
Pmo
v0
Pmu
P^m
Fm
vm
Pu
P^u
Fu
vu
0
Range vprocess to v0
 The laser uses default values
 Constant laser power
Range vm to vu
 The pulse power, pulse duration and frequency are
constantly adapted to the speed
 The laser is working in the pulsed mode
 The pulse power, frequency and average power change
Range v0 to vm
 The laser power is continuously
reduced
 The laser works in the CW mode
Range vu to 0
 The parameters use the values programmed in vu
 The laser is working in the pulsed mode
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TLS 251bn - 20.07.2009
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Cut editor and Cut database
Cut editor
Cut database
 In the cut editor, the parameter sets for
the cutting of contours, small contours
and punctures are created and saved
 Optional part of Module Cutassist
 The parameter sets can be called in
the laser porgram
 In this database are cutting parameters
for all common materials in different
thicknesses included by TRUMPF
 Cut database automatically creates all
necessary technology parameters and
 Outputs the default values to set the
machine
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TLS 251bn - 20.07.2009
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Cut editor - User inferface
1
2
3
 In the tab Piercing (3), the parameter set which
produces the start hole for a cutting process is
created.
 The tab Cutting (1) can be used to create a
parameter set to cut a mixture of big and small
geometries.
 In the bab Cutting of small contours (2) the laser
works exclusively in the pulsed mode for an optimum
cutting quality for very small geometries. Due to long
pulse breaks, the material can cool down.
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TLS 251bn - 20.07.2009
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Creation of cutting parameters without Cut database
 In the Cut editor the user assigns the necessary laser
parameters to every velocity point on the cutting path
and by doing this he creates his own material data
bank.
These default values must be observed:
- Diameter and type of laser light cable (LLK)
- Reproduction ratio of the focusing optics (focal
lengths of collimation and cutting lens)
- Cutting gas (type and pressure)
- Cutting gas nozzle (diameter and distance to the
workpiece)
- Process velocity
- Focal position
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TLS 251bn - 20.07.2009
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Creation of cutting parameter sets with Cut database
 In the existing material data bank Cut database the
user chooses type of material, thickness, collimation
and lens in the Wizard
 Further steps:
- Check the settings on the machine and on the
optics
- Create laser program
 Processing can be started
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TLS 251bn - 20.07.2009
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Module Cutassist - Example: quality improvement
Material:
Mild steel
2mm
Laser:
TruDisk 1000
5mm
Velocity:
54 m/min
Without Module Cutassist
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009
With Module Cutassist
30
How to get Module Cutassist
 Module Cutassist can be used with all CW-lasers using the TruControl 1000
control unit, e.g. TruDisk and TruFiber
 You can either order Module Cutassist directly with your new laser device or easily
upgrade it at a later date
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TLS 251bn - 20.07.2009
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Example (1)
medical tweezer; stainless steel 0.5 mm
 No cutassist, only pulsing
 With cutassist, cw and pulsing
 11 s
 7,4 s
110 mm
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Example (2)
latch of a cabinet; mild steel 2 mm
 Pulsing with cutassist: corner intact
 CW with power control : corner damaged
10 mm
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TLS 251bn - 20.07.2009
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Cutting with picosecond pulses
 Pulses short enough to vaporize
material
 Free space beam guidance
 Scanner for fast beam steering
 Cutting = repeated scribing
(or scribe + break)
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TLS 251bn - 20.07.2009
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Cutting with picosecond pulses
Cutting of Nitinol
 Small cutting kerf (< 10-20 µm)
 Negligible HAZ
 High quality of cutting edge
 No electro polishing!
 High yield
 High productivity due to high average
power
 Application: Cutting of Stents,
endoscopes
TruMicro
TRUMPF 5000
Disk Laser
© TRUMPF
Applications
- CONFIDENTIAL
TUS260sw
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Cutting with picosecond pulses
Cutting of Silicon Wafers
 Small cutting kerf (< 20 µm)
 Negligible HAZ
 High quality of cutting edge
 High productivity due to high
average power
 Applications: Waferdicing
TruMicro
TRUMPF 5000
Disk Laser
© TRUMPF
Applications
- CONFIDENTIAL
TUS260sw
TLS 251bn - 20.07.2009
36
Cutting with picosecond pulses
Cutting of Silicon Wafers
 Small cutting kerf (< 20 µm)
 Negligible HAZ
 High quality of cutting edge
 High productivity due to high
average power
 Applications: Waferdicing
TruMicro
TRUMPF 5000
Disk Laser
© TRUMPF
Applications
- CONFIDENTIAL
TUS260sw
TLS 251bn - 20.07.2009
37
Cutting with picosecond pulses
Scribing and cutting of Ceramics
 Small kerf width (< 20 µm)
 Negligible HAZ
 High quality of cutting edge
 High productivity due to high
average power
 Applications: Scribing / cutting of
ceramic PCBs
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TLS 251bn - 20.07.2009
38
Cutting with picosecond pulses
Scribing and cutting of Ceramics
 Small kerf width (< 20 µm)
 Negligible HAZ
 High quality of cutting edge
 High productivity due to high
average power
 Applications: Scribing / cutting of
ceramic PCBs
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TLS 251bn - 20.07.2009
39
Cutting with picosecond pulses
Scribing and cutting of thin glass
 Small kerf width (< 20 µm)
 Negligible HAZ
 High quality of cutting edge
 High productivity due to high
average power
 Application: Scribing/cutting of
thin glass for Flat-Panel-Displays
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TLS 251bn - 20.07.2009
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Cutting with picosecond pulses
Cutting of thicker glass
Glass Cutting
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Thank you for your attention!
David Locke
TRUMPF Laser Technology Center
47711 Clipper Street
Plymouth Twp., MI 48170
[email protected]
TRUMPF Disk Laser Applications
TLS 251bn - 20.07.2009