Fiber Vs. CO2 Laser: Pros and Cons

After the invention of computer-controlled machines, CO2 lasers gained a lot of popularity in the market. Later on, fiber lasers came into the market. Both these machines have their own advantages and disadvantages when we compare their speed, cost, precision, and more. And so, the manufacturing industries often feel confused when choosing between Fiber and CO2 laser cutters. To make it easier for you, we have explained both the laser machines and including pros and cons.  

What is a Fiber Laser Cutting Machine?

The CNC machine controls the light source from the resonator and delivers it to the cutting head. The laser is emitted from the end of the cable and refocused to a series of focal lenses on the cutting sheet. The fiber laser has cutting gasses like NO2 and O2 around the material, which helps in vaporizing the intense heat and blowing away the dust particles.

 

Fiber lasers are generally used for etching, engraving, and metal annealing. As they produce small focal diameters (which means higher intensity), it is suitable for the high contrast markings like serial numbers, barcodes, data matrices on the metals, etc. They are often used for product traceability by directly marking the product parts.

 

The fiber machines require less maintenance and have a long service life. Also, using good quality spare parts like Mitsubishi laser consumables or Trumpf laser consumables will increase the shelf life of the parts. The size of the machine is smaller than the CO2 lasers. Also, the electrical efficiency of the fiber laser is high, so it significantly uses less power than CO2 lasers, which means substantial cost savings. 

 

Apart from cutting, fiber lasers are also used for industrial cleaning applications like removing dust, paint, oxides, and any kind of contaminants.

 

What is a CO2 Laser Cutting Machine?

The light from the CO2 resonator is refocused by using a series of lenses for the reflection process. Here the cutting head emitted light. The path of the reflection process is protected with laz gasses to keep the path clean and dust-free. Thus, this beam path delivery system ensures no dust interferes with the delivery, and the laser path passes with full intensity. 

 

The CO2 laser is ideal for a wide range of non-metallic materials like textiles, plastics, glass, acrylic, wood, and stones. It is also used in pharmaceutical and food packing. We can also use it for marking PVC pipes, mobile gadgets, electrical appliances, integrated circuits (IC), and electrical components. The CO2 lasers are best for cutting thicker materials. 

 

For all materials above 5mm, CO2 laser can deliver faster piercing, straight-line cutting, and a smooth finish. The one drawback of the CO2 laser is that it consumes more power when compared with the fiber laser, which means higher cost of operation. Last but not the least, make sure to use good quality Trumpf, Amada, or Mitsubishi replacement parts for better cut quality.

 

Pros and Cons of CO2 and Fiber Laser Cutter

 

Advantages of CO2 Laser

1. The CO2 lasers leave the best edge quality specially for aluminum and stainless workpieces.
2. They can also be used for cutting non-metals.
3. As these technologies have been in use for so many years, the results are predictable, and the user has assurance of the quality of the cuts.

 

Disadvantages CO2 Laser

1. The CO2 laser requires a blower, chiller, and beam path delivery system to ensure the working of the laser beam. All these processes consume a lot of power and, thus, it is costly.
2. You require regular maintenance of the system, which adds up to the cost.
3. It is not the best choice when it comes to cutting thin materials.

 

Advantages of Fiber Laser

1. The fiber laser cutting system is cheaper compared to CO2 lasers.
2. With the use of mirrors, gasses for the beam path delivery system, the cost of maintenance is reduced. And the consumables from good brands like Mitsubishi replacement parts, and Amada replacement parts can be easily found online.
3. The fiber laser is way faster than the CO2 laser.
4. They consume less power compared to CO2 lasers.

 

Disadvantages of Fiber Lasers

1. Fiber lasers do not give a proper finish while cutting thicker materials compared to CO2 lasers.
2. They are compatible with cutting non-metals.
3. They are not as known and familiar to the users as the CO2 lasers.

 

Conclusion

The choice is yours; if your business requires cutting non-metals, then go for CO2 lasers, and if you require a cost-effective and faster machine, you must go for the fiber laser cutter. Both the laser machines are best in their own way, and to keep receiving the best performance from both, it is important to maintain them. For that, you can use good quality Mitsubishi laser consumables, Trumpf laser consumables, etc. Suitable quality consumables will last longer, and you will receive good quality cuts for a more extended period of time.

 

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/fiber-vs-co2-laser-pros-and-cons

Top 5 Tips to Maintain a Fiber Laser Cutting Machine

There is a lot that goes behind the metal fabrication business. The fiber machine requires a proper way of maintenance in order to receive the best cuts. Thus, proper maintenance of the machine will save you from troubles in the future. And if it requires major changes,then you might have to halt the production. This will cause waste of money and time. So here are some maintenance tips for the fiber laser cutter machine.

Regular Cleaning

Cleaning is a basic yet essential process to prolong life of a fiber laser cutting machine. You can divide the cleaning task in three different ways: daily, monthly, and yearly. Let us discuss some of the daily cleaning tasks. It is the job of the operator to clean the device. They should empty the slag bins and drawers after every cut because if they do not then it is possible that the drawer might jam. All the surfaces must be cleaned so that new sheets can be placed on a clear surface.

The next step is examining the torch. The torch is the nucleus of the fiber laser cutter and its malfunctioning can affect the quality of the cut and damage the machine as well. Also, the cleaning torch helps in making the most precise cuts. So, it is important to clean the torch, nozzle, cables, and the surrounding windows. To clean these, the operators must use a microfiber towel or a lint free cloth. After a while, some spare parts like conical nozzle, chrome nozzle, lens, etc. will require a change.

The area around the machine must also be kept clean. This will ensure no one trips over those things and injures themselves. Ensure all the connections are secured and there is no loose wire. These simple verification practices can help you save from future headaches.

Temperature Maintenance

Fiber laser vaporizes metal with heat to cut the material. The operators must try to keep the equipment cool. The coolers must be checked regularly to ensure they are working properly. Its filters, fans, and coolant levels must be cleaned. If the machine overheats, then it can cause issues to the machine and its spare parts. So it is important to keep track of the temperature.

Ensure Gas Leakage

Fiber laser uses machines to operate and vaporize the material. If the gas is contaminated then the quality of the cut depreciates. So for a smooth cut, the gas must be as clean as possible. If the operators observe a leak, they must change the bottle as soon as possible. Because ignoring the situation can cause more damage and affect productivity and also pose risk to the lives present there.

Align the Machine

To get the straight cuts, it is important that the machine is aligned properly. The operators can check the verticality of the machine every few weeks or when they find any uneven cuts. If the cuts are not smooth or if the material is not cut the way through then the operators must adjust the alignment of the machines accordingly.

Miscellaneous Tasks

The operators must ensure that the parts that require lubrication are properly lubricated. If any parts require oil change then it must be changed regularly. Also, the belts must be tight enough to have  proper hold. Any parts that require regular replacements like conical nozzle, chrome nozzle, lens, etc. must be changed.

Conclusion

The fiber laser machine can serve you for years if it is well maintained. Regular checking of parts reduces the chances of failure. This will save time and money that goes behind those repairs. Also, use the materials that are compatible with your laser machine or else it can damage the machine as well.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/top-5-tips-to-maintain-a-fiber-laser-cutting-machine

3 Types of Laser Cutting Machine

Laser cutting has been in the market since decades now and has been updated a lot in these years. The lasers use a constant beam of light to create the heat and pressure to cut, mark, drill, or engrave the material. With the CNC machines, all the processes are stable and precise.

There are different types of laser machines that have different ways to concentrate the light beam and different materials that can be used with it. They are CO2 Lasers, Fiber Lasers, and Crystal Lasers. 

The manufacturers suggest regular maintenance of these machines and usage of good quality spare parts. Thus, it is recommended to use trumpf laser consumables, amada laser consumables, etc. for quality parts.

To know more about different types of lasers, keep reading.

CO2 Laser

A CO2 laser uses a gas mixture of carbon dioxide, nitrogen, hydrogen, and helium to produce a light beam. The gas mixture is filled in a tube that contains mirrors on each ends. One of the mirrors in the tube is fully reflective and the other is partially reflective allowing some light to pass. The invisible light produced comes under the infrared range of the light spectrum.

Usually the CO2 lasers are 25 to 100 watt in power and the wavelength is 10.6 micrometers. To enhance the power of the CO2 beam, oxygen content can be boosted. This can be risky if the machine is not suitable for such enhancements and the operator is new to this technique. The CO2 lasers are the best for non-metallic materials. This laser is commonly used for cutting or engraving wood, paper, leather, fabric, and acrylic plastics.

The other important task to do is to maintain the laser machine. The regular maintenance helps in receiving the precise cuts. The regular change of consumables is the solution. You can easily find good quality trumpf laser consumables, amada laser consumables, etc.

Fiber Laser

The fiber laser amplifies the light beam with the specially designed fibers which are derived from pump diodes. The wavelength is 1.064 micrometers which produces small focal diameters. The fiber lasers are expensive but the maintenance cost is extremely less. 

Also, they have a long service life of 25,000 laser hours. Thus, the life of fiber lasers is far more compared to the other two types. To ensure that the laser has a long shelf life, it is important to maintain it properly. For that, you can regularly check and change the spare parts. You can use good quality trumpf laser spare parts, prima laser parts, amada spare parts, etc.

Fibers are suitable for metal marking and engraving. It is also suitable for non-metals and alloys and even glass, wood and plastic. With variable power, these lasers can deal with a variety of materials.

Crystal Laser

Crystal laser uses nd:YAG (neodymium doped yttrium aluminum garnet) or nd:YVO (neodymium doped yttrium orthovanadate) crystals. The wavelength of the laser is 1.064 micrometers and are useful for medical, dentistry, military and manufacturing. 

The nd:YVO has:

• higher pump absorption
• a broader bandwidth and wavelength for pumping
• shorter lifetime
• higher refractive index
• lower conductivity

The nd:YAG has similar performance but the only difference is that it does not allow high pulse energy as that of nd:YVO. These lasers are useful for both coated and non-coated metals. It can also be used for plastics and ceramics.

Conclusion

All these lasers have their own way of functioning and are suitable for different types of materials. To always receive the same good quality results, it is necessary to have a maintenance schedule. You can make schedules on a daily, monthly and yearly basis. The parts that require replacement must be replaced with the parts from renowned companies. For example, trumpf laser spare parts , amada laser spare parts, etc.  

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/3-types-of-laser-cutting-machine

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