Home / Laser, Waterjet, Plasma Cutting Systems

Laser, Waterjet, Plasma Cutting Systems

A yearend review of some of the current advances and application capabilities in each of these metal cutting technologies.

Posted: November 5, 2014

An Eagle fiber laser cutting head with laser beam from MSS Lasers is one of the most advanced systems in the market, with linear drives on all three axes and a low inertia carbon fiber transverse bridge construction that can accelerate up to 6G with achieve cutting speeds in excess of 100 m/min.

Accuracy inside the Eagle fiber laser from MSS Lasers is assured through the rigidity of the carbon fiber bridge and the dynamic polymer concrete frame that minimizes vibration and heat related deflection of the machine geometry. With bed sizes up to 6 m x 2.5 m, this system increases material utilization by efficiently nesting jobs and cutting very large parts.

The SUPER TURBO-X laser-cutting system with Preview 3 control from Mazak Optonics uses proprietary vibration dampening frame and integrated laser resonator that ensure stable, high accuracy cutting of plates. The constant beam length construction provides uniform cutting performance across the machine table.

The TruLaser 8000 2D laser cutting machine from TRUMPF can process material up to 52 ft long and up to one inch thick using a 6 kW laser, making it ideal for processing very large parts or for job shops looking to expand their capacities and range of services.

KBM separate rotor and stator packages on ProLaser CL laser cutting systems from Proteck are supplied in kit form and directly mounted on the machine within their own bearing system and protective cover, with power and encoder connectors built-in. The mounting arrangement directly couples the large diameter pinion shaft to the rotor as a single solid assembly, restricting lost motion and potential unwanted harmonics that a flexible coupling may allow.

On ProLaser CL laser cutting systems from Proteck, S700 servo drives with multi-feedback capability from Kollmorgen are used with both resolver feedback, mounted on the KBM motor for commutation, and magnetic linear scales for the position loop. The feedback protocol is SSI absolute, EnDAT or alternatively BiSS, to suit a choice of CNC controllers with set-up and monitoring via EtherCAT that is integrated in all S700 drives.

With a maximum sheet size of 3.1 m x 1.6 m, next-generation ProLaser CL flat sheet cutting machines from Proteck also use AKM series rotary servo motors with Micron™ series planetary gearheads that are brake fitted for the Y-axis as well as the Z-axis.

The highly rigid MicroMAX JetMachining® Center from OMAX has a table size of 2 ft 4 in x 2 ft 4 in and an X-Y cutting travel of 2 ft x 2 ft. Its new Mini Tilt-A-Jet® cutting head nearly quadruples the position accuracy of the nozzle for even more precise cutting with virtually zero taper in most materials up to 3 in thick. The head is also 25 percent smaller and lighter and nearly twice as rigid for less deflection.

Intelli-MAX 21 for JetMachining Centers from OMAX not only optimizes tool paths automatically, it provides precise predictability of cutting speeds, taper, jet lag and other abrasivejet factors of those particular tool paths to achieve the highest levels of waterjet cutting speed and performance.

Supplied with a MAXJET 5i nozzle, the high precision A-Jet cutting head from OMAX cuts accurate beveled edges at angles determined by either the machine operator or part program. The A-Jet adds two motion axes, enabling the nozzle to tilt over a range of 0 deg to 60 deg from the vertical position. It can be used to easily produce beveled edges or cut countersunk holes, as well as machine parts with complex geometries. With its additional axes of motion, the A-Jet allows production of beveled edges in preparation for welding operations. The use of this accessory eliminates the need for many secondary machining and grinding operations.

With a Rotary Axis, JetMachining Centers from OMAX have up to 6-axis cutting capabilities that can create accurate complex 3D parts from pre-existing CAD drawings or DXF files. With the expanded parametric shape library, the Rotary Axis is ideal for pipe and tube cutting, simplifying challenging projects such as intersecting pipe fittings.

FlowXpert 2015 is a robust CAD/CAM software platform from Flow International that introduces significant new waterjet capabilities for 3D pathing and cutting that allow shops to work more effectively and with less complexity in 3D.

The DynaBeam laser height sensing technology from Flow maps the natural state of materials, reducing the need for manual adjustment throughout cutting. Operators can choose between setting the standoff height between the waterjet nozzle and the workpiece before every pierce, or pre-mapping an entire workpiece quickly and easily.

The price of a build-it-yourself WARDKit from WARDJet includes everything necessary to start waterjet cutting, including the tank, cutting head, grates, intensifier pump, control software, human machine interface and access to technical support. Upgrades and options on pump horsepower, controller style, and abrasive delivery system allow perfect configuration.

The Emerald 0606, the smallest waterjet ever manufactured by WARDJet, is designed to offer all the quality of a large, expensive waterjet cutting system at a reduced size and cost. Because of its rigid, sturdy tank design, the Emerald 0606 is capable of handling 12 in thick stainless steel just as easily as a 2 in sheet of foam.

The J-Series is a low-cost water-only waterjet from WARDJet that uses belt drive technology to cut at speeds of 2,500 ipm with an acceleration and deceleration rate of 0.2 m/s2. J-Series waterjets are ideal for cutting high volumes of parts where margins are low and tolerances are not as demanding.

The L-Series, the fastest cutting waterjet from WARDJet, uses a linear motion drive system with excellent accuracy, repeatability and reliability that cuts 7,000 ipm with an acceleration and deceleration rate of 1 sq m. The thick-walled steel tubing frame of the L-Series can accommodate multiple 5-axis cutting heads.

The FARM-JET waterjet cutting system from Jet Edge brings the power and versatility of ultra-high pressure waterjet cutting technology to farm machine shops for the price of a new fully loaded 1 ton 4X4 pickup truck, without requiring special electrical service.

The affordably priced direct-drive style Eco-Jet PTO ultra-high pressure waterjet pump is ideal for rural machine shops or areas with limited power because it utilizes a tractor PTO shaft to produce ultra-high pressure water for precision cutting, cleaning and surface preparation. It runs a .015 in waterjet orifice and can power most waterjet cutting systems and waterjet tools.

The economically priced BOSS-CUTTER water jet cutting system from Jet Edge is ideal for small shops. It has a 40 in x 40 in (1 m x 1m) work envelope with one abrasivejet cutting head and a motorized Z-axis with 5 in (513 mm) of travel that is controlled with a Windows PC (sold separately) and uses a FlashCut Pro-Series Stepper Controller and FlashCut CNC software. It also includes IGEMS path generation software and a hand-held controller pendant for operator convenience.

The compact SGX automated plasma and oxy-fuel cutting machine from ESAB features the easy-to-use Vision® T5 touch-screen CNC with built-in automatic nesting, as well as automatic gas controls and plasma automation powered by m3 Plasma technology. Performance and accuracy are assured with a heavy steel beam, precision machined mating surfaces, and linear rail. This rugged design ensures smooth motion, accuracy and long term machine durability. SGX enables higher productivity with rapid cut-to-cut cycle times through the integration of dual-side, high-speed AC drives and a fast torch lifter.

The do-it-yourself V Series Plasma from MultiCam features a custom-engineered, extruded aluminum frame with steel leg supports for high strength and rigidity. Automatic torch height is standard along with powerful, dual X-axis drive motors and Hypertherm PowerMax plasma torches. The easy-to-use, handheld operator interface features graphic icons for all machine functions.

The V-PRO CNC Plasma system from MultiCam has a standard, heavy-duty, all-steel water table with integrated bladder capable of production processing of sheet steel up to 1.25 in thick without the need for fume evacuation. The CNC plasma system uses a Hypertherm MAXPRO200 (200 amp) power supply engineered for heavy-duty, high capacity mechanized cutting.

The compact, durable 5-axis bevel plasma head from MultiCam uses aluminum castings for weight reduction and rigidity, has improved crash protection and ease of maintenance, and introduces the “phi” and “theta” axes of movement for cutting complex parts with bevels up to 45 deg in 2 in thick mild steel.

Designed to remove up to 25 lb of metal per hour, the PAK 200i manual gouging and plasma cutting system from Victor Thermal Dynamics can also hand cut 2 in thick mild steel at 10 ipm.

LASER CUTTING

HIGH SPEED, HIGH POWER FIBER LASER CUTTERS
Well known for its expertise in laser and nitrogen generation technology, MSS Lasers Ltd. (Rugby Warwickshire, UK) has expanded its fiber laser cutting capabilities with the Eagle eVision and iNspire range of fiber laser machines, sharing its knowledge and experience in a close partnership with the manufacturer. These machines are some of the most advanced in the market, giving users linear drives on all three axes and a low inertia carbon fiber transverse bridge construction that enables the Eagle to accelerate at up to 6G and achieve cutting speeds in excess of 100 m/min.

To make the most of the high cutting speeds, table change times are less than 10 seconds, minimizing idle time between sheets. This combination of rapid cutting and fast changeover makes the Eagle range of fiber laser cutters some of the most productive and profitable for users. For maximum versatility, customers can choose from different laser power options from 2 kW up to a maximum of 6 kW, which makes it one of the highest power fiber lasers currently available on a commercial machine and ideal for the fast cutting of thick material.

Accuracy is assured through the rigidity of the carbon fiber bridge and the dynamic polymer concrete frame which minimizes vibration and heat related deflection of the machine geometry. The Eagle range comes in bed sizes up to 6 m x 2.5 m, enabling it to cut the largest sheets. This extra bed size allows companies to cut very large parts and also benefit from more efficient nesting, increasing material utilization rates.

The design of the fiber laser eliminates the use of CO2 gas and many of the components such as the turbine, mirrors and bellows necessary on a CO2 machine, greatly reducing maintenance requirements and the overall footprint of the machine. Power consumption is also around 70 percent less than a CO2 machine enabling customers to make dramatic savings, especially valuable with increasing energy costs.

Further advantages include rapid start up and shutdown of the machine, minimizing delays at the start of a shift, and the ability to cut reflective materials such as copper and brass and also plastic coated materials, thanks to the frequency range of the fiber laser.

MSS Lasers is a privately owned pioneer in the supply of high pressure nitrogen generation plants for laser cutting. Not only does this save users the cost of purchasing gas, but it also has environmental and operational benefits by providing nitrogen on demand at the customer’s premises.

The company was formed in 2003 by managing director Carlos Gonzalez-Lee, whose research and experience in laser cutting, along with the need for an independent specialist laser company in the UK, provided the springboard for the company’s growth in its core business of servicing and sales of all types of refurbished laser cutting machines and, now, the supply of Eagle fiber laser cutting machines. The company has developed partnerships across Europe, especially in Spain, where it is also distributing the Eagle machines.

MSS Lasers Ltd., Units 9-12, Allerton Road, Central Park Rugby, CV23 0PA United Kingdom, 01 788 5522 99, Fax: 01 788 5533 03, sales@mss-lasers.com, www.mss-lasers.com.

AUTOMATED LASER CUTTING OF PLATES
Mazak Optonics Corporation (Elgin, IL) offers the new SUPER TURBO-X laser-cutting system featuring the new Preview 3 control. It is the ideal solution for plate applications, especially where material automation is a consideration. The SUPER TURBO-X is built on the industry’s most reliable laser platform, with a rugged hybrid design and an easy access table. It features a proprietary vibration dampening frame and integrated laser resonator that ensure stable, high accuracy cutting. The constant beam length construction provides uniform cutting performance across the machine table.

The Preview 3 control greatly improves the machine’s operation efficiency by automatically determining the ideal processing conditions for each material type and thickness. It offers smooth, high-speed responsiveness and optimum acceleration and deceleration to reduce cutting times. It also features a user-friendly 15 in touch screen with a high-quality display to view 3D cutting path graphics.

The machine’s new Opti-Pod offers automated setup features that help minimize preparation time and improve extended unattended operation. These are intelligent functions designed to both automate and help maintain optimized machining conditions for increased productivity. SUPER TURBO-X series machines are available in 2.5 kW and 4.0 kW CO2 configurations, with table size options of 2412 (49.21 in x 98.43 in), 3015 (60.04 in x 120.08 in) and 4020 (78.74 in x 157.48 in).

Mazak Optonics is a major supplier of laser-cutting systems, offering 50 laser models and leading the industry in the implementation of emerging laser technologies from its 50,000 sq ft North American headquarters in Elgin, where a 30,000 sq ft laser technology center houses up to 18 machines for demonstrations and training.

The company is part of Yamazaki Mazak Corporation (Oguchi, Japan), the global leader for the manufacture of machine tools and systems for the precision machining of metal parts, including CNC turning centers, horizontal and vertical machining centers, Multi-Tasking machining centers, turnkey cells and software solutions. The North American headquarters for Yamazaki Mazak are located in Florence, KY.

Mazak Optonics Corporation, 2725 Galvin Court, Elgin, IL 60124, 847-252-4500, sales@mazaklaser.com, www.mazakoptonics.com.

LARGE-FORMAT 2D LASER CUTTING
Built especially to handle oversized formats, the TruLaser 8000 laser from TRUMPF Inc. (Farmington, CT) cuts sheet metal up to 52 ft long. The machine is the ideal solution for companies processing very large parts or for job shops looking to expand their capacities and range of services. The customer has the option to choose between two pallet concepts and six format sizes, ranging from 8 ft x 20 ft to 8 ft x 52 ft.

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This newly designed 2D laser cutting machine offers many innovative features, including the optional AdjustLine function that modifies the cutting process using specially developed cutting tables to increase the tolerance for variations in material quality. The optional CoolLine function uses water to remove excess heat created while cutting to achieve far superior cutting results when dealing with low-grade material.

This large-format machine also grants a 0.2 in increase in the maximum thickness for mild steel and stainless steel. Fabricators are now able to process this material, up to one inch, using a 6 kW laser. The single cutting head strategy makes it possible to cut all material thicknesses without changing out the head.

With the new design, the machine’s control concept has also been enhanced. The user interface has been significantly simplified, as the machine now features self-explanatory, dialog-based touch command. The ergonomic control panel can be adjusted for operator preferences and the lighting conditions in the production area.

A cabinet for the machine’s accessories is located directly below the control console, ensuring nozzles, lenses and cleaning sets are always at hand. The high-efficiency cooling unit increases energy utilization, as does the updated laser standby mode. When the TruLaser 8000 suspends cutting, the laser reduces the amount of power it draws by 40 percent, yet stands ready to resume cutting in just seconds. The LensLine feature automatically checks the condition of the focusing lens, increasing its service life and eliminating unnecessary cleaning cycles. Clearly marked maintenance points, easy access locations and clear maintenance instructions contribute to the speed and ease of service.

Also, as of the end of October 2014, standard machines in the TruLaser Series 5000 will be able to cut through stainless steel up to 2 in thick. And when fitted with the BrightLine option, 2D laser cutting machines can considerably improve the quality of the edge on stainless steel sheet at gauges between 0.8 in and 1 in thick. This is made possible with TruFlow 8000, a CO2 laser that delivers 8 kW of power, and a mirror cutting head. The higher laser output is especially designed for shops that work stainless steel and aluminum.

To make full use of the laser’s high output, TruLaser machines with the TruFlow 8000 are equipped with a mirror cutting head. Since the heat-related effects are less than with lenses, the mirror-based optical system is reliable even if a considerable amount of dust has collected. As a result, cleaning is required less frequently and the wear rate at the mirror is distinctly less.

An added benefit is found when the enhanced laser power is combined with the BrightLine function. This option uses a special mirror head with a foot-long focal length to produce clean and smooth edges, even in stainless steel up to 1 in thick. With its newly increased laser output, the machine is especially beneficial for companies processing a large quantity of thick-gauge stainless steel. Applications include making blanks for machining or cutting parts that could previously only be done with plasma or water jet equipment.

With the ability to cut stainless steel up to 2 in thick, the machine easily prepares blanks for subsequent machining operations. Instead of milling the part from bar material with a great deal of waste, the laser cuts the contour out of a plate of sheet metal, meaning several different shapes can be efficiently nested together to save material and machining time.

TRUMPF Inc., 111 Hyde Road, Farmington, CT 06032, 860-255-6104, Fax: 860-255-6424, susan.grohs@us.trumpf.com, www.us.trumpf.com.