CO2-Laser - FDP. Dr.-Ing. Eckhard Beyer.pdf · from CATIA-files generating the cutting program ... Weld ing speed (m/min) 4 kW 6 kW ... Design surface tension construction

sbey:05_10_55_1_bey.ppt

Fraunhofer InstitutWerkstoff- undStrahltechnik

IWS

Forum AutoVision Wolfsburg

CO2-Laser

Eckhard Beyer Fraunhofer IWS Dresden

Markus LingnerRofin-Sinar Laser GmbH



IWS


Main application areas of lasers

Today Tomorrow

2D cutting CO2 laser 3D cutting CO2 laser

2D welding CO2 laser3D welding Nd:YAG-laser

Soldering diode laserHardening diode laserCladding diode laser



IWS

Forum AutoVision WolfsburgTh

e po

wer

of l

ight

CO2-Slab-Laser

66--SepSep--05 W. 05 W. RathRath

Optional with donut mode



IWS


3D laser cutting machine with linear drives (company Arnold )



IWS


3D laser cutting machine with linear drives (company Arnold )

• control: Siemens 840 D

• linear drives: 1FN3

• acceleration: 2 g

• feed velocity: 100 m/min

• positioning accuracy: <0,03 mm

• repetition accuracy: <0,01 mm

• working area: 4,2 m x 2,5 m



IWS


3D laser cutting of a BMW A-pillar

cutting parameter

• material: DC04, 1,5 mm zinc coated

• cutting velocity: 10 m/min

• positioning velocity : 20 m/min

• laser power: 1500 W

• focal length: 127 mm (5“)

result:

• cutting time: 91 s

Video



IWS



Video



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Axis configuration of the 3D cutting machine12-axis treatment withsimultaneous double 5 axis-transformation

3D-distance-control inworking area with overlaidfast short-stroke-axis

twin-laser-treatment

4-axis:torque drivesv = 1000 rpm

4-axis:torque drivesvs = 1000 rpm

4-axis:linear drives

v = 100 m/min

4-axis:linear drives

vs = 100 m/min

6-axis:rotary

s

2-axis:toothed belt drives

v = 60 rpm

2-axis:toothed belt drives

vs = 60 rpm

6-axis:linear

3D-cutting machine with

12 axis

s

s

2-axis:spindle drivesv = 30 m/min

2-axis:spindle drivesvs = 30 m/min

control:Siemens 840 D

2-channels

s



IWS


Process chain 3D laser cutting

customer IWS

CO2 laserCO2 laser

Fiber laser

Fiber laser

• Cutting of different materials

• No secondaryprocessingtime

• High dynamic cutting of largeconstruction unitswith excellentpositioningaccuracy

construction unite. g. deep drawing

body prototype

generating thecutting program

with FasTrim from CATIA-files

generating thecutting program

with FasTrim from CATIA-files

3D-geometriesin CATIA-format

• large dimensions

• complex 3D-geometries

• Teach-Innotnecessary



IWS


140

2

4

6

0 1 2 3 4 5 6 7 8 9 10 11 12 13

penetration (mm)

Wel

ding

spe

ed(m

/min

)

4 kW6 kW

8 kW

Welding of Mild Steel St 52 f=300 mmGas: He


14

12

10

8



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penetration depth [mm]

0,

2

4

6

8

10

12

14

0 2 4 6 8 10 12 14

wel

ding

spe

ed (m

/min

)

GaussDonut


Welding of Mild Steel St 52 f=300 mm Gas: He



IWS


2D laser weldingAdvantage of a gaussian mode for thinner laser seams at butt joint welding

Advantage of a donut mode for wider laser seams at overlap welding




IWS


Laser welding of powertrain components

1

1 mm

Process laser powerprocessing speedfocussing parameter

Materialpreheatinginductor geometryfiller wire

Design surface tensionconstructionstiffness



IWS


Trends in layout, construction, function and production of powertrain components

Critical welding applications

cast iron

80-55-6

case hardened

steel4320

case hardened

steel4320

case hardened steel / quenched and tempered steel

cast iron / quenched and tempered steel

cast iron / Cast iron

quenched and tempered steel/ mild steel quenched and

tempered steel1045



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Welding with filler wire

leading position

trailingposition

Video



IWS


laser beam

cast iron

case hardenedsteel

Problem:

Reasonable production of differentials

Laser beamwelding

Laser beam welding+ filler wire

1 mm 1 mm



IWS


laser beam

cast iron

case hardenedsteel

Laser beam welding withmaterial adapted filler wire

Problem:

Reasonable production of differentials

Video



IWS


Laser welding production machine

IWS - Patent



IWS


Welding defects by insufficient cleaning of the joint geometryparticle

grease

oil

workpiece

Soiling of the joining area

cleaning area

Laser cleaned



IWS


particle

grease

oil

workpiece

Soiling of the joining area

cleaning area cleaning area

scanner

CO2 laserlaser power 2,5 kWintensity 106 w/cm²

Laser cleaning



IWS


Main application areas of lasers

Today Tomorrow

2D cutting CO2 laser CO2 laser, (fiber laser)3D cutting CO2 laser fiber laser, (CO2 laser )

2D welding CO2 laser CO2 laser, (fiber laser)3D welding Nd:YAG-laser fiber laser

Soldering diode laser diode laserHardening diode laser diode laserCladding diode laser diode laser



IWS



Higher torque at reduced dimensionshigher loading stresseshigher strength materials

restricted weldabilityHigher functional integration

more complicated shapematerials well-tolerable against sensor functions

welding of dissimilar materials

Welding in the finally machined stateminimum heat inputminimum distortionreduced residual stresses

laser welding



IWS



Critical welding applications

Industrial solutions

• Laser welding withfiller wire

• Laser induction technologycase

hardened steel4320

cast iron

80-55-6

case hardened

steel4320

quenched andtempered

steel1045



IWS


Solution: Laser beam welding withmaterial adapted filler wire

100

200

300

400

500

600

700

800

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Weg in mm

Här

te H

V 0

,3

100

200

300

400

500

600

700

800

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Weg in mm

Här

te H

V 0

,3

without filler wire with filler wire

ductile zone

case hardened steel4320

cast iron80-55-6



IWS


Laser welding and cleaning machine

Video



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0

2

4

6

8

10

12

14

0 1 2 3 4 5 6 7 8 9 10

Welding stainless steel f = 200 mmDC 045 4,5 kW Helium

Gauss

penetration depth (mm)

wel

ding

spe

ed(m

/min

)

7,0 m/min

12,0 m/min

Donut

Donut

Gauss66--SepSep--05 W. 05 W. RathRath



IWS


Laser beam welding with filler wire

leading position

Video

trailingposition

Key-hole opening during laser beam welding with filler wire



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Step 4: simulation

• Kollisionstest des Schneidkopfes

• Einsatz der Bereinigungsoperationen

- Joggen

- Interpolieren

- C-Achsoptimierung

- Events

- Kreise über 3 Pkt.

Documents

CO2-Laser - FDP. Dr.-Ing. Eckhard Beyer.pdf · from CATIA-files generating the cutting program ... Weld ing speed (m/min) 4 kW 6 kW ... Design surface tension construction