Laser Cutting vs Plasma Cutting: The Ultimate Comparison

The invention of CNC machines has made the cutting process more efficient compared to manual cutting methods. The manufacturers or the businesses that require cutting processes are highly inclined toward these two most famous computer-controlled processes known as Laser Cutting and Plasma Cutting. There are advantages and disadvantages that both these cutting methods have when we compare the thickness of the material, type of material, the precision of the cut, cost, etc. Let us understand both these methods in detail and then compare it to know which suits your business requirement the best.

What is Laser Cutting?

Laser cutting is a cutting technology controlled by computer numerical control (CNC) to slice materials by the amplified laser light. It has a high precision rate as it is controlled by a CNC machine and not manually.

 

The cut is made on the metal by focusing the laser light on a small point using the optics. When the laser light enters the optical lens, it will become smaller and hotter. The temperature at the focused point increases which melts and cuts the workpiece leaving the edge smooth and of a high-quality finish.

 

What is Plasma Cutting?

The plasma cutting involves cutting through electrically conductive materials by using an accelerated jet of hot plasma. It can melt any hard material. It has been in use for decades and is still one of the best cutting methods.

The one thing about plasma cutting is that it works only for electrically conductive materials like stainless steel, steel, brass, aluminum, and copper. Plasma is extremely hot during the process as it uses ionized gas and not naked flame. The temperature is usually determined by the plasma torch. It also uses a CNC machine to control the whole cutting process, leaving smooth finish cuts.

Advantages & Disadvantages of Laser Cutting

Here are some advantages of the laser cutting machine when compared to some general cutting methods:

1. The cuts are so precise and smooth that they can be directly used for cutting without grinding.
2. The laser cutting machine is faster than other cutting processes like plasma cutting.
3. The cutting quality of laser machines is much higher and it leaves behind minimum deformation, low surface roughness, and minimal oblique cutting edge.
4. Apart from metal, it can also be used to cut wood, plastic, rubber, PVC, textile, leather, etc.

However, the laser cutting has a couple of disadvantages as well:

1. The laser cutting machine is a little expensive as the initial investment and the maintenance are costly.
2. Laser cutters have lower efficiency when it comes to thick plates which means it is more suitable for thin plates.

Advantages & Disadvantages of Plasma Cutting

Here are some points where plasma cutting has an edge over laser cutting.

1. It is highly suitable for thick plates. It can achieve high cutting speed when compared to laser and flame cutting.
2. The initial investment is lower compared to lasers. Moreover, the maintenance cost is also low.

 

There are a few disadvantages of the plasma cutting machine which make it less favorable than the laser cutting machines.

1. The plasma cutter has poor perpendicularity and it will leave a large oblique cutting edge.
2. It produces slag at the bottom of the cutting process during the cutting. To maintain the quality of the cut, this slag must be removed by grinding which adds up the labor cost.
3. During the cutting process, it releases harmful dust and arc light.
4. It consumes more cutting nozzles which cost a lot of money.

Laser Cutting Vs Plasma Cutting: Comparison

1. The laser cutting machine makes lesser damage to its workpiece when compared to the plasma cutting machine. The plasma cutter requires frequent changes of consumables like nozzles and torches. The damaged consumable can cause damage to the cutting plate and affect the quality of the cut as well. So while using the plasma cutting machine, ensure to use good quality consumables like amada laser parts, trumpf laser parts, prima consumables, etc.
2. The laser has more focused light whereas the plasma has a slightly larger cutting point. So small cuts are more clearer and precise in laser than in plasma.
3. The speed of the laser cutting is more than that of the plasma cutting machine.
4. The laser cutting machine leaves behind smooth and good quality cuts. Also, it produces less heat during the cutting. Thus, there are lesser chances of thermal deformation of the workpiece, saving the material from any kind of damage. Also, the edge is perfect which avoids any kind of secondary process. The only thing you need to be careful of is the thickness of the plate as plates of higher thickness do not perform well with laser cutters.
5. The accuracy of the plasma cutter is less but the maintenance and environmental requirements for cutting are less compared to laser. So for products that do not require high precision, plasma is the most cost-effective choice as the maintenance cost is low. Good quality consumables like amada parts, trumpf consumables are easily available online. Also, the skill requirement is low and it is easy to operate for the operators.

Conclusion

Every business has its own requirements. Some businesses require the use of non-conducting materials, then for them, laser cutters are the best. On the other hand, some businesses have thick sheets to cut, then for them, plasma cutting is preferable. If the type of material is not the issue then budget might be an issue because just buying the machine is not enough. 

To enjoy getting the best output from the machine, it is important to maintain the machine. You can easily find the amada parts, trumpf and prima parts online. For that, all you need to do is Google “amada laser parts” or “trumpf laser parts” and you will have a list of the suppliers. 

We hope these comparisons will help you choose the cutter that fits best your needs.

Source:

https://altpartsinc.wixsite.com/altpartsinc/single-post/laser-cutting-vs-plasma-cutting-the-ultimate-comparison

How to Maintain a CNC Machine

We all are familiar with the machines like lathe, milling, drilling, etc. These machines require human involvement to perform and be monitored. This way, it consumes more time and has less accuracy. To overcome this problem CNC (Computer Numerically Controlled) machines were manufactured.

 

CNC machines can be defined as the machines that are controlled by computer and the operations are performed by inserting the program. You can consider them as the brain of the whole manufacturing process.

 

This makes it even more important to maintain them, because if it goes down, all the other processes will stop working. Such failures can cost businesses thousands of dollars because they have to instantly find the replacement parts, manage missed deliveries, etc. 

 

To avoid such situations what we can do is focus on the maintenance of the machine on a regular basis. And if any part requires replacement you can easily find good quality Mazak parts, Fanuc parts, etc. online.

 

Moving further, let us learn about CNC machine maintenance in detail.

What Parts of CNC Needs Maintenance?

The maintenance of the CNC machines is not as complicated as it sounds. It is simple but critical as no company can afford the cost a small mistake can cause. Hence, here is the complete list of the maintenance steps you need to consider.

 

Coolant: The parts of the machine move fast and this means it will generate heat. So a fixed coolant level must be maintained otherwise these parts can get damaged. If they get damaged you can find good quality Mazak parts, Fanuc parts, etc. online.

 

Cooling Oils: The speed of the spindle is around 10,000 RPM and it is obvious that it will produce heat. Thus, to avoid this thermal energy a right cooling system with the right concentration of oils is needed.

 

Lubrication: The moving parts of the machine can get dry and might need lubrication to reduce unwanted friction. Thus, using oil or grease on the parts moving smoothly. The other fluids like hydraulic fluid in the CNC machine also need replacement. If the machine consumes fluid excessively, then it indicates that the machine may have some problem.

 

Surfaces: The grime will build up on the surface if not cleaned regularly. To ensure a clean working environment, a good grip and proper visibility in the room, clean windows, doors, handles, etc. are important.

 

The other thing that you need to care about is the sound of the machine. If the machine is having any slight mechanical failure, it will sound differently. You should always consider it as a red flag and check it intensively. And if any parts need replacement, you can easily find Mazak replacement parts, Fanuc replacement parts, etc. online.

 

How Often Do You Do Maintenance Checks?

A CNC machine’s sensors, detector system, etc. also gives signals if anything is wrong. Apart from that you must indulge in a routine based on the hours of machine used. To save yourself from doing all the tasks at once, you can divide these tasks strategically.

 

We have made a list for you but can change the time intervals as your work requirements and usage of the machine. 

 

Daily Maintenance tasks:

• Check lubrication levels and refill if needed

• Any part that looks dry must be greased

• Check coolant concentration and level; add more if required

• Empty chip hopper

• Check hydraulic system levels

• Clean surface and the surroundings

 

Monthly Maintenance:

• Clean or replace air filters

• Clean coolant filters

• Clean radiators

• Clean cooling fans

• Review the checklists for unusual oil consumption

• Adjust chains or conveyors

 

Yearly Maintenance:

• Completely remove coolant tank and take out metal chips to check for bacterial growth

• Inspect and clean the system

• Check hydraulic oil for contaminates

• Replace filters

• Drain and clean lubrication unit and refill new oil

• Check drawbar tension and chuck cylinder

• Replace the X and Y axis gibs if needed under backslash program

 

Wrapping Up

All CNC machines perform different tasks but the processes like coolants, lubrications, filters, etc. are common for almost all CNC machines. Even if a small breakage happens your in-house team will be able to repair it in no time if you already have replacement parts of your CNC machine handy. You will easily find the Mazak replacement parts, Fanuc replacement parts, etc. Hence, this way it ensures your delivery schedule is not affected.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-to-maintain-a-cnc-machine

Press Brake Machines: Types, Advantages, and Disadvantages

Initially the press breaks were made from custom cast iron, oak and a manually operated leaf that would force a clamped piece of sheet metal to be bent. Fast forwarding to today, the making of press brakes has highly evolved with advanced computer technology and hydraulic systems. That is why press brakes these days can easily, efficiently, and safely bend the sheets.

Press brakes work with a die and punch that are set at a particular angle to bend or cut the metal in various shapes and forms. The total pressure that can be applied during the bend is known as tonnage. The higher the tonnage, the thicker the material can be bent.

So for proper fabrication the material size and thickness, tonnage and bending length are required. These factors will determine the load limit of the press brake and it is calculated in tons per inch.

Now, let us understand the types of press brake machines and later on some advantages and disadvantages of it.

Types of Press Brake Machines

A lot of things have changed in the press brakes mechanism over time. Modern press brakes require less effort and are much safer compared to earlier models. Also, modern brakes have improved speed, efficiency, and quality of bending metals. There are three types of modern brakes namely manual, hydraulic, and CNC press brakes. 

Manual Press Brake

Manual press brake is the most common type of press brake and is also called sheet metal brake. They require manual adjustment of bending dimensions and angles. The manual break consists of a worktable, supporters and a clamping plate. Supporters consist of a base, pressure plate and the worktable is mounted on it.

However, manual press brakes are more complex to operate compared to other press brakes as all the adjustments in it are done manually. So, once the bending size and angles are confirmed then only you can start mass production. And then, after completing the first batch you can do new adjustments and start the production again. 

Hydraulic Press Brake

These brakes utilize two hydraulic cylinders and it provides consistent strokes and more control. 

They can be classified based on the types of movement:

• Up Acting

• Down Acting

These are also classified based on synchronization:

• Electro-Hydraulic Synchro

• Torsion Synchro

• Hybrid

CNC Press Brake

These brakes have the highest precision and customization ability. It utilizes computer technology to increase the efficiency and also control the accuracy. The adjustments like bending angle, width, plate thickness, and number of pieces are inserted on a controller by an operator. 

Once the machine starts it does the rest of the things. CNC press brakes generally adopt a hydro-electric servo system and a grating ruler. It consists of a machine frame, workbench, oil cylinder, CNC controller, and hydraulic proportional servo system.

Some parts of the press brakes require replacements after it is worn-out. It is wise to replace such used press brake parts on time or else it will affect the performance of the machine. You can easily find trumpf press brake parts, amada press brake parts, accurpress press brake parts, etc. online.

Advantages

• The press brakes are suitable for small batch and multi variety production. One die set is used to complete the production of some parts and materials that possess strong applicability.

• The shelf life of each set of die is long and the manufacturing cost of bending the die is low.

• It can do the production of S and U shapes.

• It is easily adaptable to new products, without increasing cost.

• It can complete the multibend production of shapes like polygon.

• It adjusts deflection compensation value so that bent is in a straight line that too without manual adjustments. Thus it is simple to handle even a long workpiece.

Disadvantages

• The thickness of the material required to be formed must not be more than 50 mm.

• It can fracture or crack material during bending due to the oxide layer formed at the edges and corner during cutting.

• It can produce large indentation while bending due to inappropriate die and can increase cost.

• Sometimes the materials slip or do not move as they should while bending resulting in material failing to meet the process standards.

 

Conclusion

Press brakes serve a wide range of industries like auto, aviation, energy, agriculture, transportation, military and many more. The production needs and material defines the type of brakes required for proper forming. You can choose one that we discussed above as per your needs. Also, you will require to change used press brake parts that need replacement. Ensure to buy those from the respective brands only. You will easily find amada press brake parts, trumpf press brake parts, etc. online.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/press-brake-machines-types-advantages-and-disadvantages

How Does CO2 Laser Cutter Work?

Laser cutting is used everyday by the manufacturing industry for cutting metals. CO2 laser cutters changed the game. These lasers are not only useful for the manufacturing industry but also for the medical field and artists. 

The manufacturing industry uses it for cutting and engraving. The medical industry uses it for skincare, whereas the artist uses it for making art. All these industries have different machines but a common laser, i.e., a CO2 laser.

Here we will learn why industries prefer CO2 laser cutters and how it works. 

Advantages of CO2 Laser

Here are some benefits of a CO2 laser cutter.

1. Lower Power Consumption: These machines have a low maintenance cost. Also, the replacement required is inexpensive.  Fanuc CO2 lasers are popular, and you can easily find the Fanuc replacement parts online.
   
   

2. Contactless Process: The laser beam does not physically touch the material. Instead, it causes the material to melt through the intense heat produced by the beam.
   
   

3. Safe: Laser cutting is safer than other forms of cutting as the whole process is bladeless. The beam is sealed in a tight lightbox, which makes it safer.
   
   

4. Precise Cuts: The cuts produced by the lasers are highly accurate, precise, clean, and smooth. It is unlikely to see this in other cuts.
   
   

5. Applications: Laser cutters have many applications from the manufacturing industry to the medical sector. Artists also use it for engraving purposes.

How does a CO2 Laser Work?

The electricity runs via a gas-filled tube to produce light for CO2 laser cutters. The light produced by the CO2 laser is powerful compared to the usual light.

This light passes through the tube that has mirrors at both ends. One of the mirrors in the tube is highly reflective, while the other mirror allows some light to pass through it. These mirrors usually reflect most of the light when traveling through the tube. Thus, it causes the light wave to build intensity. So when the light becomes bright enough it then passes through the partially reflective mirror.

These mirrors emit the light or laser beam to the material that is to be cut. When the intense heat travels to the material, the light vaporizes the material that is to be cut. Hence, it leaves an accurate and smooth cut.

The gas produced during formation of laser and cutting process is a combination of carbon dioxide, hydrogen, nitrogen, and helium. 

Also, the light produced from the laser is infrared and thus, it is visible to the human eye. The wavelength of these beams is long so it can cut cloth, wood, glass, metal, and paper. 

While forming the cut, the laser somewhat damages the machine as well. And that is why some parts like the focus lens, battery, mirrors, etc need replacement. You can find Fanuc replacement parts online. 

Verify the Settings

There are three important settings that need attention when it comes to laser cutting.

1. Focus: There is a focus lens inside the laser head that is responsible for clean and smooth cuts. The lens needs to be changed at regular intervals. You can buy Fanuc parts online. They are easy to find and are of premium quality.
   
   

2. Speed: The speed determines how fast the laser head will move. Ensure to maximize the speed while engraving or cutting the thinner material.
   
   

3. Power: High power is used for thicker materials, and low power is suitable for engraving or thin materials. Adjust it according to the material. 

Conclusion

Now that you know how the CO2 laser beam works, consider some important points discussed above. The speed, focus, and power of the laser depend on the material. These factors will further decide how smooth and clean the cut will turn out. Also, make sure to replace the parts that need replacement. Choose brand products such as Fanuc.  Search “Fanuc parts online”, and you can easily find it from authorized dealers.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-does-co2-laser-cutter-work

8 Core Components of Laser Cutting Machine

Laser cutting machine outputs high density and high energy laser beams that concentrate on the workpiece. Thus the spot where it concentrates melts while the workpiece moves forward on the track making the cut. 

Laser cutting has replaced the traditional mechanical knife with an invisible beam. It has become popular because of high precision, faster and smoother cutting, unlimited patterns at low cost, and more. 

Thus, a laser cutter needs three things to complete the task namely machine, light and electricity. The machine is composed of the different mechanical parts, generator, CNC, lenses, etc. 

Let us discuss some of the essential components of the laser cutting machine.

Laser Cutting Head

The cutting head in the laser cutting machine is the output for the laser. It consists of a nozzle, lens, and a tracking system. The cutting head will travel on the cutting track to make the cut. You can adjust the height of the head and control it depending on the material, thickness, and various other parameters. 

The shelf life of the nozzle will also depend on whether it is properly placed and is cleaned on a regular basis. A good quality nozzle will last long. The trumpf nozzles, amada nozzles, prima nozzles, etc. are of good quality. Trumpf eco nozzle is also a good option to go with. 

Lenses

Laser lenses are the most used component in the laser cutting machine. The lenses used are of different types like full reflex lenses, focusing lenses and semi reverse lenses. They all have distinct functions.

As lenses work as one of the most important parts of the laser machine, the quality of the laser directly affects the performance of the machine.

These lenses are usually made domestically or they are imported. But the quality of the domestic lenses are not as good as the imported ones. But then when we compare the prices, domestic lenses are cheaper.

Motor

Motor is one of the core components of the laser machine. So, the performance of the motor directly affects the production efficiency of the machine.

Presently stepping motor and servo motor are the two types of motors configured in the laser machine according to the product and industry of the object. 

Stepper motor has fast starting speed as well as sensitive response to engraving and cutting processes. They are low priced. Whereas, the servo motor is for smooth movement, high load, and fast cutting speed. These are suitable for products and industries with high processing requirements.

Water Chiller

As the name suggests, water chillers are used for cooling laser generators. Basically, a laser generator is a device used to convert electrical energy into light energy. For instance, the CO2 laser has a conversion rate of 20% and the remaining energy is converted into heat. So the cooling water will take the excess heat away to make sure that the laser generator is working properly. 

The chiller also cools the external optical path reflector and the focus lens. This way, you will have stable beam transmission quality and prevent the lens from getting excessively hot, leading to deformation or crack.

Laser Cutting Frame

The frame makes sure of the movement across the X, Y, Z-axis during the cutting process. The only requirement here is that they must be highly stable. This high stability of the tools help you in improving the cut precision. 

There are three types of tools in the market namely gantry type, beam type and cantilever type. These tools have different functions like beam type is used for material cutting of large manufacturers. Automotive industry highly uses this tool.

CNC System

Computer Numeric Control (CNC) system is a leading OS of the fiber laser cutting machine. It mainly controls the tool to detect the movement of the X, Y and Z axis. It also controls the output power of the laser machine.

The quality of the system determines the stability of the laser machine. By controlling this software wisely, you can achieve accurate cuts. 

Air Cutting System

This system is composed of an air compressor, air dryer and filter devices. There are two kinds of air sources namely bottled air and compressed air. When we talk about the cost, air cutting is more economical than gas cutting. The reason behind the low cost is that air cutting saves gas consumption cost when compared to Nitrogen. 

Dust Extractor

The smoke and dust released during the fabrication process will be filtered and treated to match the environmental protection standards. And this makes dust extractor a critical component of the laser machine.

Conclusion

So, while considering laser components, do not only consider the properties of product material, but also make sure to consider the performance of the laser components. The quality of these components must be high so that it can deliver best performance for a prolonged period. Also, ensure to buy excellent quality consumables. For this, you can consider trumpf nozzles, trumpf eco nozzle, trumpf lens, amada nozzle, prima lenses,  etc.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/8-core-components-of-laser-cutting-machine

Fiber Laser Optics and Its Importance

Fiber laser cutting is used for a wide range of applications to process and produce laser quickly and efficiently with lasers. So the question is, how does fiber laser cutting machine use laser to cut? Talking about laser, how is laser produced and what is its principle?

Optics plays a huge role in the quality of cuts. You can find consumables from Prima Optics, lvd strippit parts, trumpf, etc. We have divided fiber laser cutting machines into two types: inner optics and outer optics.

Inner or Internal Optics

Let us find out what inner optics do in the laser machine.

Cutting

The laser generator releases a super-density laser beam. It is irradiated on the metal plate by a light spot. Then the cutting material is melted or vaporized at high temperature. After that, the high-pressure gas is used to blow off the melted metal and the residue.

Laser Production

Laser is converted from electrical energy to light energy. It is obvious that the conversion between the two energy cannot be 100%. Some part of it gets converted to light energy and the other is converted to heat energy. Currently, the electro-optical conversion rate of fiber lasers is 25%-35%. So better the performance of laser, the higher is the ratio of electro-optical conversion rate. So you will have lower energy consumption.

Outer Optics

Here is what outer optics do in the laser cutting machine.

Light Transmission

When the laser generates light and transmits it through optical fiber, a certain amount of energy is lost. Because the optical fiber is connected to the laser head. Also, when they are released from the fiber-optic head, they take a wavy shape. 

Waveform Light

Waveform light cannot collect or concentrate energy. With a collimator, you can process the wave light close to parallel light. 

Focusing Lens

The main function of this lens is to collect and concentrate the parallel light and form a super density light spot. 

Protective Lenses

While using a laser cutting machine, a certain amount of metal dust and debris will be generated. If they enter the cutting head of the laser machine, then it is important to protect the lens. You can replace this lens whose average shelf life is one piece per month. Needless to say, the loss depends on the intensity of the equipment. You can invest in good-quality mirrors like the reflectors from Prima Optics, Trumpf, lvd strippit parts, etc. A good quality mirror will last long.

Copper Nozzle

After the laser crosses the protective lens, it is released through the copper nozzle. On average, you might need two pieces per month. Again, the amount of loss depends on the intensity of use of the equipment. You can buy good quality spare parts from the Trumpf, Prima, LVD, etc. for your laser machine.

How to Maintain Lens?

As discussed above, we know how the lens gets damaged when you use the laser for a period of time. But to reduce this cleaning is necessary. The correct procedure to clean the lens is to use a cotton swab and dip it in the alcohol. Alcohol evaporates if any access is left on the lens. Then gently wipe the lens with it. These lenses have a layer of coating on the lens, wipe gently so that you don’t scratch. 

Conclusion

The performance of laser cutting machines depends mainly on the condition of optics. So it is important to maintain the mirrors to get the best from them. It is advisable to change the worn-out parts on time because it will directly affect the performance of the laser. Buying good quality consumables and cleaning the spare parts at the regular interval will increase its shelf life.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/fiber-laser-optics-and-its-importance