In the ever-changing world of manufacturing and metalworking, laser tube cutting has emerged as a revolutionary technique that provides unprecedented precision and efficiency. Laser tube cutting is now widely used in sheet metal processing, kitchenware, lamps, automobiles, medical devices, hardware, fitness equipment, and other industries because it can replace mechanical drilling, milling, sawing, punching, or deburring, which require equipment and hard tools for different metal tube processing, and realises the processing of complex tube structures such as blanking, chamfering, cutting grooves or holes, scoring, and other possible size and shape. Whether you are a seasoned professional or a beginner, grasping the complexities of laser tube cutting is critical for optimising production processes and expanding your business.
In this article, we’ll look at the fundamentals of laser cutting, including its benefits and contribution to modern production.
What is laser tube cutting?
Laser tube cutting is a tube processing technology that uses a powerful laser beam to precisely cut materials. A computer numerical control (CNC) system precisely moves the laser head to the surface of the material.
How does laser tube cutting work?
Laser tube cutting is the technique of selectively cutting tube stock material using a controlled precision laser to create various forms, holes, designs, and/or channels. During laser cutting, the stock (tube/pipe) is fixed on a controlled lathe and turned in accordance with the design parameters. Laser tube cutting can generate through holes of any shape, as thin as the material wall thickness, and is also commonly used to cut channels that allow tubes to be readily bent and welded into angled tubes.
Advantages of Laser Tube Cutting
The benefits of laser cutting devices should not be underestimated. Here are some of the most significant advantages that tube laser cutting provides to your business.
1. Precision & Accuracy
Metal materials are significantly more accurately cut using lasers than with traditional processing equipment such as flame cutting, plasma cutting, and water jet cutting. At the same time, different materials may exhibit small expansion and contraction deformation during processing, and laser tube cutting equipment can adapt to these deformations in a way that many older techniques cannot.
Accuracy refers to the cut parts being as near to the specified size as possible. Tube laser cutting is the process of focussing a high-power laser on a small point on the material’s surface (measured in spot diameter). Laser tube cutting equipment can maintain tight tolerances due to their small spot diameters and CNC system stability.
Precision is the capacity to repeat the same precision in all cuts. CNC systems can repeat the same motion with exceptional precision, making them an important part of laser cutting.
2. Versatility and flexibility
Traditional tube cutting is limiting and frequently lacks the fine control required for sophisticated designs. Laser tube cutting can cut any pattern on metal tubes, making it more adaptable than alternative methods.
Lasers are also excellent at cutting wall thicknesses of 1 inch (25.4 mm) or more without bending or deforming the material. Through holes pose one of the most difficult problems for any cutting process since the holes’ edges can quickly melt and bend. Lasers can readily cut holes in thick metal without producing excessive heat at the margins.
3. Higher cutting speeds
Traditional or manual tube cutting processes are inherently slow due to the requirement for human intervention. However, laser tube cutting can achieve cutting speeds of several meters per minute or greater. This is because laser tube cutting employs an automated control system that can programmatically regulate the movement trajectory and cutting speed of the laser beam, resulting in an efficient and rapid cutting operation. Furthermore, the laser can keep its speed and precision for several hours. If the cooling requirements are met, the laser cutting machine can operate indefinitely.
4. Zero material waste
Accidents or even mistakes during the cutting process might completely damage the pipe design, resulting in material waste. Laser tube cutting saves material because there are fewer mistakes during the cutting process. Even many laser tube cutting machines on the market now use a multi-chuck technology to assure no tail materials, which is unquestionably a significant decrease in material waste for manufacturing organisations that handle a big number of tubes every day.
5. 0 tool wear
Mechanical tube cutting devices, such as grinders, electric saws, and hydraulic blades, wear down after frequent contact with metal workpieces. Laser tube cutting is a contactless procedure, thus there is no tool wear.
6. Smoother surface
The smoothness of the cut is determined by the tool’s sharpness and the amount of heat created throughout the procedure. Excessive heat can cause the edges to melt and deform, resulting in low surface quality.
Materials Suitable for Laser Tube Cutting.
Laser tube cutting works with a wide range of materials. Laser technology can be used to precisely cut and create tubes made of metal, plastic, wood, or even paper.
Metal and Alloy Compatibility
- Aluminium
- Brass Copper Stainless Steel
- Titanium alloys include nickel and chrome-plated metals, as well as aluminium, copper, iron, and titanium alloys.
Nonmetal Compatibility
- Plastics are commonly used in the pipe manufacturing and plumbing industries.
- Wooden tubes are less prevalent and mostly utilised in furniture manufacturing.
Cardboard tubes provide a low-cost support framework for toilet paper and kitchen towels.
Thickness and Size Limitations
Machine size and laser configuration are the primary factors determining laser tube cutting capability. The following are the general thickness and size limits for this technology.
- Maximum Cutting Length: 60 inches (18m).
- Maximum tube diameter: 24 inches (610 mm).
- Maximum wall thickness: 1 inch (25.4mm).
Most commercially available tube laser cutting machines can only do half of what is listed above.
Tube Laser Applications and Industries
1. Steel structure industry: Laser tube cutting equipment can be used in the steel structure manufacturing business to cut steel tubes of various sizes. It may be planned and cut using programs, which reduces the uncertainty of manual measurement and cutting, increases manufacturing efficiency, and reduces waste.
2. Automobile production: Automobile manufacture necessitates a significant amount of pipe processing, and laser tube cutting equipment may be used to cut pipes of many shapes, including round, oval, and more. Laser cutting can leave readable traces on the surface of the pipe, which is extremely valuable for future traceability and quality control.
3. Aircraft manufacturing: Laser tube cutting equipment have applications in aircraft manufacturing. When creating aircraft engine jet pipes, laser tube cutting machines can be utilised to cut pipes of various sizes and shapes. Laser cutting can minimise material waste and errors while improving cutting quality.
4. Medical equipment manufacturing: Laser tube cutting machines can be used to produce pipes for medical equipment. Laser tube cutting devices may achieve extraordinarily high cutting accuracy while reducing material waste. Laser cutting may also cut materials to the required size and shape without contact, considerably increasing the manufacturing efficiency of embedded or intelligent medical devices.
5. Furniture manufacturing: Laser tube cutting devices can be used to cut metal or plastic pipes. Laser cutting is more exact than older methods and can complete the cut without harming the pipes. Laser cutting can also provide greater assurances about the smoothness and beauty of cutting furniture.
6. Others: Industries that use stainless steel pipes include machinery production, elevators, sheet metal, kitchen equipment, chassis cabinets, machine tool equipment, electrical equipment, lighting hardware, advertising signs, car parts, display equipment, various metal goods, and sheet metal cutting and processing. It is simple to operate and use, and it increases work efficiency, resulting in lower labour costs and time.
In general, laser tube cutting machines are widely utilised in a variety of industries, owing to their high precision, high efficiency, and reliable operation.
Factors to Consider When Selecting the Ideal Laser Tube Cutter for Your Needs
The correct one is the finest. Keep these five steps in mind while purchasing a laser tube cutting machine.
1. Material Selection – The material you choose will affect the type of laser you use (fibre or CO2).
2. Tube Size – The maximum supported tube length and diameter are determined by the size of the machine table and chuck.
3. Laser Power – Laser power determines cutting speed and depth.
4. Machine Tolerance – Tolerance, also known as cutting accuracy, is the dimensional difference between a laser cut object and its input size.
5. Degrees of Freedom (DOF) – Machine The number of axes of motion (DOF) determines the motion and versatility of a laser cutting machine. Machines with more axes cost more.
In conclusion
Laser technology advancements have considerably enhanced tube laser cutter productivity while also lowering entry prices. Today, organisations can reap numerous benefits from transitioning to laser-based tube cutting. Benefits like as faster production times and smoother surfaces are extremely significant in high-volume production. A laser tube cutting equipment is a long-term investment for your workshop or facility.
Stand out from the crowd with pendstar laser cutting machines and accompanying accessories!
Pendstar is committed to offering high-quality, long-lasting laser tube cutting machines and accessories. Whether you want to build your own brand of laser cutting equipment locally or increase the accuracy and efficiency of your manufacturing process, collaborating with us will be the best decision you ever make!
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