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Laser Machining of Complex Parts from Diamond and Composite Materials

For 3D toolmaking and aerospace work, the 5-axis LCS 305 Laser MicroJet cutting system from Synova cuts and shapes large and multi-tooth diamond tools, resulting in smooth cutting surfaces and sharp edges for PCD, SCD, natural diamond, tungsten carbide or other ultra-hard materials.

Posted: January 15, 2019

The two highly dynamic torque motor-driven rotary axes on the the LCS 305 laser system can chamfer for K-land edges and single or multiple clearance angles. Tools are exchanged quickly and accurately using the HSK 63 tool holder. With waterjet-guided laser technology, the LCS 305 can precisely machine parts made of ceramic-matrix composites used for hot section aero-engine parts while protecting the material from heat-related effects.

The LCS 305 CNC machine tool from Synova S.A. (Duillier,Switzerland) has full 5-axis capabilities that can process complex three-dimensional geometries in the machining of industrial diamond employed in toolmaking, as well as various composite materials used in aviation. The LCS 305 offers unmatched accuracy, quality and speed, with highly dynamic axes, water-cooled linear and torque motors, mineral casting machine bed and fully automatic offset calibration system. Its flexible Laser MicroJet® (LMJ) system enables 3D cutting and shaping of large and multi-tooth diamond tools, resulting in smooth cutting surfaces and sharp edges for ultra-hard materials such as PCD, SCD, natural diamond or tungsten carbide. The machine’s two highly dynamic torque motor-driven rotary axes also allow chamfering for K-land edges and single or multiple clearance angles. Tools can be exchanged quickly and with a high degree of accuracy thanks to the HSK 63 tool holder.

Only the LCS 305 laser system with waterjet-guided laser technology is capable of precision machining parts made of ceramic-matrix composites (CMC, a composite made of SiC) while protecting the material from heat-related effects. The low weight and heat-resistant new material is used for hot section aero-engine components to increase aircraft efficiency. “The issue of heat affected zones and micro-cracks is greatly alleviated when using these unique Laser MicroJet systems because of the inherent heat dissipation properties of the waterjet,” says Dr. Bernold Richerzhagen, the founder and chief executive officer of Synova. “The LMJ has already been successfully deployed for the drilling of holes and cutting of CMC shrouds and has proven the necessary precision and reliability required for such applications.”

The LMJ ‘wet laser’ technology cools workpieces while efficiently washing away debris. The waterjet maintains the laser’s focus, creating a cylindrical laser beam that results in parallel walls and tight kerf widths. The LCS 305 is a complete CNC system that includes SynovaCut 5.0 CAD/CAM software and SmartFactory functions, such as an integrated laser power meter, positioning sensor and automatic jet angle correction. It can be flexibly incorporated into production as either a standalone system or into automated lines for operator-free high volume production.

Synova USA, 1 Harmon Plaza, Suite 102, Secaucus, NJ 07094, 510-396-5664, jcoderre@synova-usa.com, www.synova.ch.