Macchina da taglio laser CO2

Basicinformation

Introduction

Inthefieldofnon-metallasermarking,solidlasermarkingmachinesandgaslasermarkingmachines(CO2Lasercuttingmachine)Non-metallasercuttingmachinegenerallyreliesonthelaserpowertodrivethelasertubetoemitlight.Throughtherefractionofseveralreflectors,thelightistransmittedtothelaserhead,andthenthefocusinglensinstalledonthelaserheadconvergesthelightintoonepoint.,Andthispointcanreachaveryhightemperature,sothatthematerialisinstantlysublimatedintogas,whichissuckedawaybytheexhaustfan,soastoachievethepurposeofcutting;themaingasfilledinthelasertubeusedbythegenerallasercuttingmachineisCO2,thiskindoflasertubebecomesCO2lasertube,andthelasercuttingmachineusingthiskindoflasertubeiscalledCO2lasercuttingmachine.

Ceramicsubstrateprocessingapplication

Inordertodividetheceramicsubstrateintoindependentparts,alasermarkingmachinecanbeusedtomark(drill)aseriesofpartial(unpassed)hightoleranceholes.Theseholesareapproximatelyone-thirdofthedepthofthesubstrate,generatingpreferentialfaultlinesforlaterrupture.Usingothertechniques,itisalsopossibletoprocessvias,slots,anddeterminetopographyandfinepatternsonthesubstrate.

Duetotheabsorptioncharacteristicsofcommonlyusedceramics,CO2lasershavebecomethelaserofchoice.TheenergyofthepulsedCO2laserbeamisabsorbedontheceramicsurface,therebycausinglocalheating,meltingandvaporization.Figure2showsatopviewofa0.0045inchscribelineinalumina,showingthatduringtherelativelylongpulse(approximately75-300m,dependingonthethickness),underthelowenergyedgeoftheGaussianbeamenergyprofile,becauseHeataffectedzone(HAZ)causedbylocalmelting.

Formanyyears,CO2laserswillconsumealotofresourcesintermsofgasandenergywhenworkinginlongshifts,andrequireamaintenanceplan.Inaddition,thepulseparameterstypicallyusedinthisapplicationmeanthatthesealedtubeCO2lasertechnologyisnotsuitable.Onthewhole,afteryearsofextensiveimprovements,CO2lasersarestillbehindothertechnologiesintermsofreliabilityandmaintenanceissues.Duringmaintenance,thebeamqualityoftheselasersisstilleasytochange;thesmallestspotsizethatcanbeachievedisalsosusceptibletolongwaves.Individually,thelaserbeamabsorptioncharacteristicsofceramicshaveallowedthistechnologytoinfluencethismarketforalongtime.

Newscribingtechnology

PreviousattemptstoapplyNd:YAGlaserstothescribingprocesswereunsuccessfulbecausetheabsorptionof1.064μmwastooweak;therewasnotenoughenergydepositedonthesurfacelayertoproduceThedesiredeffect.Tothisend,SynchronLaserService(locatedinSouthLyon,Michigan,USA)hasdevelopedsurfacetreatmenttechnologytoenhancetheabsorptionoflaserlightbyceramicsinashorterwavelengthrange.Thisprocessquicklyandslightlydipsintotheceramicsurfaceandintensifiesthedepositionenergyofthenear-infraredlaserpulseatashortenoughdistancetoproducethenecessarymeltingandvaporization.Combiningthispatent-pendingsurfacetreatmenttechnologywiththefiberlasertechnologyofSPILasers(locatedinSouthampton,UK),theprocessperformanceachievedfarexceedstheprocessperformancethatcanbeachievedbyusingaCO2lasermarkingmachine.

Surfacetreatmentgreatlyenhancesthefiberlaserbeamintotheceramictopsurfacetostartthedrillingprocess.Theenhancedpoweroftheinteractionbetweenthelaserpulseandthesurfaceofthematerial,combinedwithacustomizedhigh-resolutionbeamdeliverysystemthatensuresconsistentspotsizeonthesurface,meansthatsmallertopographycanbeachievedontheceramicsubstrate.Synchronalsoconsideredsomeotherexistinglasertechnologies,hopingtobeabletoprocessevenfinerscribing;buttheconclusionisthatnotechnologycanachievethetargetspeedinitsownuniqueway,insomecasesatleast10timesslower.

ComparedwithCO2lasers,fiberlasersshowbetterconsistencyandreliability,andcanprocessfinertopography,includingthreetimestheedgequalityafterfractureabove.Figure5furthershowstheedgequalitythatcanbeachieved.Herewedescribetheoriginaledgecreatedbycuttingthearrowshape.Importantly,thenewprocesscanevenachieveproductionspeedsthatcannotbeachievedwithCO2lasers.

Ona0.0150inchthickaluminumoxidesubstrate,thescribingspeedexceeds1300inchesperminute,whichisabouttwicethatofaCO2laser(both30%deep);butthemachiningspeedisatleasttheaveragevalue.Inmostcases,thespeedexceedsthatofCO2lasers.AccordingtoSynchron,theuseofmobilecontrolsystemsinsteadoflasershasledtolimitedproduction.

Aluminumoxideandaluminumnitrideceramicscanbeprocessedinthisup-to-dateway.Whenaluminaisused,theprocesslimitisuptoasubstratethicknessofabout0.060inches,althoughthickermaterialsforharsherapplicationsarerequiredforlongerperiodsoftime.Thickersubstratescanalsoprovidemoreheatdissipation,forexampleinhigh-brightnessLEDapplications.

Aluminumnitrideceramicsaregenerallymoredifficulttoprocessthanaluminabecauseofbetterthermalconductivity,soprocessingrequiresproportionallygreaterpower.Ontheotherhand,afinermorphologycanbeachieved,becauseonlythehighestdensitypartofthebeamcanproducetherequiredprocess,andthehighthermalconductivityofthematerialminimizestheHAZonbothsidesofthebeamenergyprofile.Theinitialresultsofusingthisnewmethodareexcellent,andtheprocessusingthismaterialcanstillbefine-tuned.

Processimprovement

Fiberlaserscanprovideaseriesofuniquepropertiesandareusedinawiderangeofmaterialprocessing.Forexample,areliableGaussianbeamprofile(TEM00)isimportantforachievingandmaintainingaconsistentspotsizeonthesurface.Fiberlasersperformwellinthisrespect,andalloutputpowersexhibitaparticularlyhigh-qualitybeamdistribution,thusallowinglargeworkingdistances(independent).Anotheradvantageisthatthesmallspotsizeandthehigh-qualitylightbeamareconvertedintothehigh-brightnesslightofthefocalpoint,whichrealizesreliableprocessing,highaccuracy,andminimumHAZ.

Fiberlaserscanjointlyachievethegreatestreductioninoperatingcoststhroughthefollowingseveralways:reducedmaintenancecosts,noalignmentorcalibrationrequirements,longeruptime,andimprovedproductionqualityathigheryields.Fiberlasersarecompactanddurable,sotheyaresuitableforthemostchallengingindustrialenvironments.

Synchron'sproprietarytechnologyhasbrokenthroughanewfieldoftechnologicalprogressintheindustry,thatis,itcannotmatchtheprocessingofothermaterialsintheproductionofconsumerelectronicproducts.Therearerelativelyfewindustrygiants.Ontheonehand,thecostofcompetitionishigh,andontheotherhand,itisnecessarytomaintainflexibilityandchangeincustomerdemand.Facedwiththissituation,anytechnologicaladvancementmayleadtowinningimportantmarkets.

Thereducedprofilesizeachievedbythecombinationoffiberlaserandproprietarysurfacemodificationtechnologyopensthedoorforfinerscribingofelectronicproduct-gradeceramicprocessing.Themonthlyoutputusuallyexceeds10millionpieces,whichcaneasilymeetthehoneycombtype.Telephonesandmusicplayers,aswellashigh-densityLEDsforbacklightingandautomotiveapplications,requiretheproductionoflarge-scaleconsumerelectronicsproducts.Infact,someindustriesarerequiringceramicsubstrateholes<0.003inches,andtheaccuracyisbetterthan0.0005inches.ItisnoteasytoachievethisresolutionwithCO2lasermarkingmachines,butSynchron’snewmethodhasbeenThislevelisreachedinmassproduction.

Surfacetreatmentcanbesprayed,dippedorrolled,anddoesnotrequirealotofdryingtime.Theapplicationofceramicsurfacetreatmentdoesnotincreaseotherprocesssteps,becausesometypesofcoatingsteps(usuallyanti-spatterlayers)aremorecommonfortheestablishedCO2processingtechnology.Inaddition,theresiduesproducedbythenewprocessarelessactiveandinsmallerquantities,whichwillonlyeliminatetheproblemofsplashing.

Processingthefinermorphologyofceramicsubstratesathigherspeedsbringsadvantagestotheelectronicsindustryintermsofdesign,performanceandcost.Fiberlaserscanhelpachieveabetterbalanceamongtheimportantcriteriarequiredbyviablecompetition:usuallyeffectiveopticalperformance,processflexibility,highoutput,long-termsystemoperation,andreliability.InthecaseofSynchron,fiberlasershelptoensurealevelofceramicprocessingperformancethatcouldnotbeachievedbefore

Other

Industrialapplications

Theworld’sfirstCO2Lasercuttingmachinewasborninthe1970s.Formorethan30years,duetothecontinuousexpansionoftheapplicationfield,theCO2lasercuttingmachinehasbeencontinuouslyimproved.ManycompaniesathomeandabroadhaveengagedintheproductionofvariousCO2lasercuttingmachinestomeettheneedsofthemarket.Two-dimensionalflatcuttingmachine,three-dimensionalspacecurvecuttingmachine,pipecuttingmachine,etc.Accordingtothe2000annualreportoftheauthoritativemagazine"IndustrialLaserSolution"fortheapplicationoflaserindustryintheUnitedStates,thetotalnumberoflasercuttingsystems(mainlyCO2lasercuttingsystems)soldintheworldin1999was3325,withatotalof1.174billionUSdollars..Althoughthedevelopmenttrendoflasercuttingisrelativelyfast,theapplicationlevelisfarbehindcomparedwithdevelopedcountries.Asof2003,thetotalnumberofCO2lasercuttingsystemsusedinindustrialproductioninmycountryhasreachedabout500,accountingforabout1.5%ofthetotalnumberofoperatingsystemsintheworld.

ExampleofCO2lasercuttingprocessparametersfornon-metallicmaterials

Material

Thickness/mm

Cuttingspeed/(cm/min)

Assistgasandpressure/Mpa

Cuttingwidth/mm

0.25

Plexiglas

10

80

N2

0.7

Polyesterfelt

10

260

N2

0.5

Threadfabric(multilayer)

15

90

N2

0.5

Cardboard

0.5

300

N2

0.4

2.6

300

N2

0.5

Quartzglass

1.9

60

0.2

Polypropyleneboard

5.5

70

N2

0.5

Polystyreneboard

3.2

420

N2

0.4

0.5

PVCboard

4

170

Air,0.15

——

plexiglass

10

120

Five-layerglueboard

5

210

1.0

Fiberboard

15.6

450

N2

——

Multilayerplywood

6.2

900

PVClaminate

3.1

1050

SawdustBoard

3.9

1800

3.1

2250

acrylamideboard

2.8

3390

3.2

2970

3.5

2720

0.05

acrylic

2.0

100

——

——

Artificialleather

0.8

250

0.3

gypsumboard

9.0

50

——

——

Plywood

10.0

110

Heatrejectionglass

2.2

50

Rubbersheet

5

50

Leather

4

220

Chemicalfibercloth

6.5

220

0.75

1200

Technicalparameters

LasertypeCO2sealedglasstubelaser

Workingplatformcrawlercuttingplatform

p>

Maximumsingle-screenengravingformatrange250mm×250mm—450mm×450mm

Motionsystemofflineoronlinemotioncontrol,5-inchLCDscreendisplay

Powersupply220V±10%50Hz

SupportgraphicformatsAI,BMP,PLT,DXF,DST,etc.

Standard500Wsmokeextractor

Optionalspecialautomaticfeeder,coldwaterMachine(notequippedwithaircooling)

Applicableindustries

SuitableforCO2lasercuttingmachinesmainlyincludespecialpartsthatrequireuniformcutting,advertisements,decorations,etc.Stainlesssteelwithathicknessofnotmorethanthreemillimetersandnon-metallicmaterialswithathicknessofnotmorethan20millimetersusedintheserviceindustry,andOneistoprocessworkpieceswithcomplexcuttingcontoursbutasmallamounttosavethecostandcycleofmanufacturingmolds.

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