Application of Laser Cutting Machines in Metal Cutting

In the field of metal processing and manufacturing, laser cutting machines are now developing towards two directions: thinner and thicker materials.

Traditional mechanical processing methods face inherent limitations in processing such materials due to contact stress, tool wear, and minimum size constraints. Laser cutting technology, as a non-contact, high-energy density processing method, has become the mainstream solution for this application scenario. Its core value lies in achieving material separation with minimal heat-affected zone through precisely controlled beam energy.

Fiber laser cutting machines are currently the main equipment for cutting thick iron plates in the market.

Advantages:

1. High electro-optical conversion efficiency (approximately 30%) and low energy consumption.

2. Good beam quality, high cutting accuracy, and good cut perpendicularity.

3. Stable operation and relatively low maintenance costs.

4. Applicable thickness range:

◦ Medium-low power (1-3kW): Can cut ≤15mm low-carbon steel plates.

◦ High power (6-20kW+): Can stably cut 30-50mm low-carbon steel, and some equipment can reach 60-100mm through process optimization (but efficiency will be significantly reduced).

Usage Recommendations

Equipment Selection: If cutting mainly involves materials below 20mm, choose a power of 6kW or less; if frequently cutting 20-40mm materials, it is recommended to choose a high-power model of 8-15kW.

Process Testing: For specific materials, conduct parameter tests first to optimize gas type, pressure, and cutting speed.

Auxiliary Measures: Perform surface rust removal and oil coating before thick plate cutting to significantly improve cutting quality and extend lens life.

Typical Application Fields of Laser Cutting Machines in Ultra-Thin Metal Cutting

1. Consumer Electronics Products:

• Smartphones/Tablets: Stainless steel/aluminum alloy middle frame antenna slots, earpiece meshes, speaker meshes, camera decorative rings.

2. Flexible Printed Circuits (FPC): Cut cover films, stiffeners, and drill via holes.

3. Smart Wearable Devices: Metal watch cases, watch straps, and internal precision structural components.

4. Medical Devices:

 • Cardiovascular stents: Laser cut stainless steel, cobalt-chromium alloy, and nickel-titanium alloy tubes to form complex grid structures. This is a typical application of ultra-fast lasers.

• Surgical instruments: Precision blade heads, fixtures, and minimally invasive instrument components.

• Medical sensors and implants: Such as metal-encapsulated biosensors.

5. Precision Instruments and Semiconductors:

• Photomasks: Metal light-shielding patterns used in liquid crystal displays.

• Lead frames: Metal carriers for semiconductor chips.

• Micro-Electro-Mechanical Systems (MEMS): Cut and form tiny metal components.

6. Automotive Industry:

• Fuel injection systems: Micro-holes on fuel injectors.

• Sensor components: Such as ABS toothed rings and pressure sensor diaphragms.

• Power batteries: Cutting of copper/aluminum foil electrode sheets (tab forming).

7. Others:

• Precision screens/filters: Used for filtration, acoustics, etc., with pore sizes as small as tens of microns.

• RF components: Waveguides, antennas, etc.

Main Challenges and Solutions for Ultra-Thin Metal Cutting

1. Thermal Deformation and Edge Burning:

• Challenge: The thinner the material, the more prone it is to warping due to heating or oxidation and yellowing of the cut edge.

• Solution: Use pulsed lasers, optimize parameters to reduce heat input; use a cooling worktable (such as a micro-hole vacuum adsorption table); use protective gases (nitrogen/argon).

 2. Micro-Residues and Re-Solidification:

• Challenge: Molten material cannot be completely blown away, resulting in slag or tiny "teardrop"-shaped residues on the back surface.

• Solution: Optimize air pressure and nozzle design; use ultra-fast lasers for sublimation/ablation processing; adjust focus position.

3. Material Support and Positioning:

• Challenge: Ultra-thin sheets are prone to sagging and shaking due to gravity or airflow.

• Solution: Use a vacuum adsorption worktable to generate uniform adsorption force on the back of the  sheet, maintaining absolute flatness and fixation. This is a standard configuration for ultra-thin material processing.