Laser Cutting Technology

Laser
Cutting technology
Issued on: 01.2007
Cutting technology © Bystronic Laser AG, 2007 0-1

ST_Laser_V20_en.fm
Laser
0-2 © Bystronic Laser AG, 2007 Cutting technology

ST_Laser_V20_en.fm
Laser
Product identification
This cutting technology applies to the following laser cutting systems:
Byspeed
Bystar
Byspint
Document identification
Cutting technology: ST_Laser_V20_en.fm
Please specify the document identification and issue date when reorder-
ing.
Purpose of this document

This cutting technology forms part of the complete set of documentation.
It provides information on the fundamentals of cutting with laser cutting
machines.
Other documents
The complete set of documentation contains the following documents:
Operating instructions
Installation Guide
Cutting technology
Spare parts catalog
Diagrams
Supplier documentation
Machine documentation
Machine logbook

ST_Laser_V20_en.fm
Laser
Target group
This document is intended for the owner of the machine and for program-
ming and operating personnel.
Storage
This document must always be freely accessible to the specified target
group.
Copyright
Dissemination or duplication of this document, or exploitation or commu-
nication of its content without the express permission of the copyright
holder is prohibited. Contravention will result in damages. All rights re-
served.

ST_Laser_V20_en.fm
Laser
Argentina Australia
BEHRENDT MAQUINARIAS S.A. LMC LASER SERVICE PTY. LTD
Lima 355 - Piso 8 Factory 2
AR-1073 Buenos Aires 1 Frias Road, Moorabbin
Tel.: +54 11 5031 5312 AU-3198 Victoria
Fax: +54 11 5031 5301 Tel.: +61 3 9555 5525
Email: info@bmaq.com.ar Fax: +61 3 9555 2970
Email: sales@lmclaser.com.au
Austria Brazil
BYSTRONIC AUSTRIA GmbH BYSTRONIC DO BRASIL Ltda.
Wienerstrasse 131 Rua Arapongas, 285
AT-4020 Linz BR-83040 200 São Cristóvão
Tel.: +43 732 341 377 0 São José dos Pinhais - Paraná
Fax: +43 732 341 377 11 Tel.: +55 41 3398 2000
Email: office@bystronic.at Fax: +55 41 3398 1789
Email: bystronic@bystronic.com.br
China China
BYSTRONIC CO., LTD BYSTRONIC MACHINERY CO. LTD.
Rijing Road 88, Level 1 Part A Economic Development Zone
Waigaoqiao FTZ Pudong Ninghe County
CN-200131 Shanghai CN-301500 Tianjin, PRC
Tel.: +86 21 5868 0480 Tel.: +86 22 6958 9988
Fax: +86 21 5868 0481 Fax: +86 22 6958 8168
Email: byadmin@sh163.net Email: sales@afmtianjin.com
Czech Republic England

CANMET s.r.o. BYSTRONIC UK LIMITED
Karlova 37 Maple Park
CZ-61400 Brno Lowfields Avenue
Tel.: +420 5 4542 4542 GB-Leeds LS12 6HH
Fax: +420 5 4542 4543 Tel.: +44 113 222 8112
Email: info@canmet.cz Fax: +44 113 271 9862
Email: service.cutting.uk@bystronic.com
France Germany
BYSTRONIC FRANCE SA BYSTRONIC DEUTSCHLAND GmbH
Parc Technipolis Mollenbachstrasse 33-35
3 avenue du canada D-71229 Leonberg
F-91940 Les Ulis Tel.: +49 (0)7152 6090 0
Tel.: +33 1 6941 9984 Fax: +49 (0)7152 6090 11
Fax: +33 1 6941 9951 Email: info@bystronic.de
Email: info@bystronic.fr
Greece Hungary
ADECA SA AUTOREL Kft.
Technical and Commercial Company Attila ut 131 / III. 12.
Ave. Alexandras 56 HU-1012 Budapest
GR-11473 Athens Tel.: +36 1 212 7270
Tel.: +302 10 822 8503 Fax: +36 1 212 7271
Fax: +302 10 821 6746 Email: sales@autorel.hu
Email: adeca@otenet.gr

ST_Laser_V20_en.fm
Laser
Israel Italy
ALON Laser Services Ltd. BYSTRONIC ITALIA SRL
23 Robinzon St. Via del Lavoro 30
IL-49560 Petach-Tikva I-20030 Bovisio Masciago / MI
Tel.: +972 3 931 0127 Tel.: +39 0362 59931
Fax: +972 3 931 0128 Fax: +39 0362 5941 35
Email: alon_ch@zahav.net.il Email: services.it@bystronic.com
Netherlands North America

BYSTRONIC BENELUX BV BYSTRONIC INC.
Stek 8 Bystronic North American Headquarters
NL-3371 Hardinxveld-Giessendam 185 Commerce Drive
Tel.: +31 (184) 611 020 Hauppauge, NY 11788
Fax: +31 (184) 617 774 Tel.: +1 631 231 1212
Email: info@bystronic.nl Fax: +1 631 231 1040
Email: info@bystronicusa.com
Mexico Poland
Bystronic Mexico S.A. de C.V. BYSTRONIC POLSKA Sp. z o.o.
Lago Onega No. 424, Col. Granada Al. Krakowska 38
MX-11520 Mexiko, D.F. Janki
Tel: + 52 (0)5 525 815 147 PL-05090 Raszyn
Fax: +52 (0)5 525 815 156 Tel.: + 48 22 331 37 70
Email: info@bystronicusa.com Fax: + 48 22 331 37 71
Russia / Ukraine and Rest CIS Singapore

Bystronic Russia Sales Office BYSTRONIC PTE. LTD.
c/o United Machinery AG 2 Leng Kee Road #03-05
2. Hutorskaja Street, 38 A Thye Hong Centre
RU-127287 Moscow SG-159086 Singapore
Tel.: +7 (495) 961 21 67 Tel.: +65 6472 6300
Fax: +7 (495) 961 21 68 Fax: +65 6472 2418
Email: sales.ru@bystronic.com Email: bystronicasia@bystronic.com.sg
Slowakei South Africa

CANMET s.r.o. FOREST ENGINEERING
Bôrik 5 P.O.Box 169
SK-811 02 Bratislava ZA-1600 Isando
Tel.: 00421 245 24 28 96 Tel.: +27 11 397 4050
Fax: 00421 245 24 77 50 Fax: +27 11 397 4210
Email: info@canmet.sk Email: forest@fhmt.co.za
South Korea Spain / Portugal

BYSTRONIC KOREA, LTD BYSTRONIC IBERICA, S.A.
6Fl, Teleron B/D Avenida Tenerife No. 2
KR-1459-2 Gwanyang-dong, Dongan-gu Edifigo 1 3A Planta Oficina D
Anyang-si E-28700 San Sebastian de los Reyes
Geonggi-do Tel.: +34 91 654 4496
Tel.: +82 314 25 5729 Fax: +34 91 652 4983
Fax: +82 314 25 0057 Email: info@bystronic.es

ST_Laser_V20_en.fm
Laser
Sweden Switzerland
BYSTRONIC SCANDINAVIA AB BYSTRONIC SALES AG
Östra Bangatan 18 Industriestrasse 21
SE-19560 Arlandastad CH-3362 Niederönz
Tel.: +46 (0)8 5944 1550 Tel.: +41 (0)62 956 37 83
Fax: +46 (0)8 5944 1555 Fax: +41 (0)62 956 33 81
Email: info@bystronic.se Email: info.sales@bystronic.com
Taiwan Turkey
CHASER C.D. ENTERPRISE CO. LTD LASERPRESS LTD.
22F, No. 639, Chung Cheng Rd. Kiremitdere
TW-238 Shuh Lin City - Taipei Hsien Dedeoglu Cad. No. 60
Tel.: +886 22 689 7988 TR-34805 Beykoz
Fax: +886 22 689 7986 Istanbul / Turkiye
Email: chaser@tpts5.seed.net.tw Tel.: +90 (0)216 413 7677
Fax: +90 (0)216 425 2341
Email: info@laserpress.com.tr
Rest of the World

BYSTRONIC LASER AG
Industriestrasse 21
CH-3362 Niederönz
Tel.: +41 (0)62 956 3333
Fax: +41 (0)62 956 3386
info.laser@bystronic.com

ST_Laser_V20_en.fm
Laser

ST_Laser_V20_en.fm
Laser
Table of contents
1 Definitions and ranges
1.1 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

1.1.1 Part area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.1.2 Parts size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.2 Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1.2.1 Maximum cuttable sheet thicknesses . . . . . . . . . . . . 1–6
1.2.2 Minimum distance from sheet edge . . . . . . . . . . . . . 1–7
1.2.3 Smallest cuttable bores . . . . . . . . . . . . . . . . . . . . . . 1–8
1.2.4 Joint width / minimum joint width . . . . . . . . . . . . . . 1–9
1.2.5 Parts distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 10
1.2.6 Hole patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 12
1.3 Achievable precision and quality . . . . . . . . . . . . . . 1 – 13
1.3.1 Parts precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 13
1.3.2 Quality of the cut edge . . . . . . . . . . . . . . . . . . . . . . 1 – 15

ST_Laser_V20_enTOC.fm
Laser
Table of contents
2 The laser cutting process
2.1 Laser cutting areas . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.1.1 Laser fusion cutting . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.1.2 Plasma cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.1.3 Laser gas cutting . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.1.4 Laser sublimation cutting . . . . . . . . . . . . . . . . . . . . 2–7
2.2 Cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.2.1 Gas parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.2.2 Cutting gas consumption . . . . . . . . . . . . . . . . . . . . . 2–9
0 - 10 © Bystronic Laser AG, 2007 Cutting technology

Laser
Table of contents
3 Design and manufacture
3.1 Factors influencing the manufacturing process . . . 3–3

3.2 Material specification . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.3 Design guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.3.1 Sheet formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.3.2 Cutting gap width for laser cutting . . . . . . . . . . . . . . 3–5
3.3.3 Orthogonality of the cut face . . . . . . . . . . . . . . . . . . 3–6
3.3.4 Roughness of the cut edges . . . . . . . . . . . . . . . . . . . 3–7
3.3.5 Contour radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.3.6 Sheet thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 10
3.3.6.1 Select small sheet thicknesses . . . . . . . . . . . . . . . 3 – 10
3.3.6.2 Select equal sheet thicknesses . . . . . . . . . . . . . . . 3 – 10
3.3.7 Common separating cut . . . . . . . . . . . . . . . . . . . . . 3 – 11
3.3.8 Hanging hole for the paint shop . . . . . . . . . . . . . . . . 3 – 12
3.3.9 Edge deformation . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 12
3.3.10 Cut-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 13
3.3.11 Tongues (bent parts only) . . . . . . . . . . . . . . . . . . . . 3 – 14
3.3.12 Relief cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 15
3.3.13 Intermittent limb . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 16
3.3.14 Tongue and slot joints. . . . . . . . . . . . . . . . . . . . . . . 3 – 17
3.3.15 Marking similar parts . . . . . . . . . . . . . . . . . . . . . . . 3 – 18
Cutting technology © Bystronic Laser AG, 2007 0 - 11

Laser
Table of contents
4 Programming
4.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4.2 Technology wizard . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.2.1 Functionality examples . . . . . . . . . . . . . . . . . . . . . . 4–6
4.2.2 Adaptations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 10
4.2.3 Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 10
4.2.4 Guidelines for piercings . . . . . . . . . . . . . . . . . . . . . . 4 – 11
4.2.5 Guidelines for initial cut types . . . . . . . . . . . . . . . . . 4 – 13
4.2.6 Technology on the contour . . . . . . . . . . . . . . . . . . . 4 – 16
4.3 Piercing and initial cuts . . . . . . . . . . . . . . . . . . . . . 4 – 18
4.3.1 Outer contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 19
4.3.2 Inner contour (cut-outs) . . . . . . . . . . . . . . . . . . . . . 4 – 20
4.4 Using process macros . . . . . . . . . . . . . . . . . . . . . . . 4 – 21
4.5 Radii on inner and outer contours . . . . . . . . . . . . . 4 – 22
4.6 Cutting-time calculation . . . . . . . . . . . . . . . . . . . . . 4 – 23

Laser
Table of contents
5 Cutting parameters

5.2 Adapting cutting parameters . . . . . . . . . . . . . . . . . 5–6
5.2.1 Reasons for parameter adaptations . . . . . . . . . . . . . 5–7
5.2.2 Requirements for parameter adaptations. . . . . . . . . . 5–7
5.3 Optimization of cutting parameters . . . . . . . . . . . . 5–8
5.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.3.2 Focal position, cutting . . . . . . . . . . . . . . . . . . . . . . . 5 – 10
5.3.3 Altering the focal position . . . . . . . . . . . . . . . . . . . . 5 – 11
5.3.4 Laser power, cutting . . . . . . . . . . . . . . . . . . . . . . . . 5 – 12
5.3.5 Gas pressure, cutting . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
5.3.6 Feed rate, cutting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 14
5.3.7 Nozzle clearance height for cutting . . . . . . . . . . . . . . 5 – 15
5.4 Cutting with laser source 5 200 W . . . . . . . . . . . . . 5 – 16
5.4.1 Focal position and beam diameter . . . . . . . . . . . . . . 5 – 16
5.5 Cutting parameters for different dimensional units 5 – 18

Laser
Table of contents
6 Machining process

6.2 Various technologies. . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.3 Cutting structural steel . . . . . . . . . . . . . . . . . . . . . . 6–5
6.3.1 Machining large sheet thickness in structural steel . . . 6–7
6.3.1.1 piercing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.3.1.2 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.3.1.3 Large parts / large sheet thickness . . . . . . . . . . . . 6–8
6.3.1.4 Example 1: Cutting in one pass . . . . . . . . . . . . . . 6–9
6.3.1.5 Example 2: Cutting in two passes . . . . . . . . . . . . 6 – 10
6.3.1.6 Example 3: Residual grid cut as heat separation . . 6 – 12
6.3.1.7 Unsuitable parts for production . . . . . . . . . . . . . . . 6 – 14
6.3.2 Cutting of structural steel with nitrogen (N2) . . . . . . . 6 – 15
6.4 Pulsed cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 16
6.4.1 Pulsed cutting (application examples) . . . . . . . . . . . . 6 – 16
6.4.2 Pulsed piercing (application examples) . . . . . . . . . . . 6 – 17
6.4.3 Recommended values . . . . . . . . . . . . . . . . . . . . . . . 6 – 18
6.4.4 Parameter adaptations for complex contours . . . . . . . 6 – 20
6.4.4.1 Adapting the cutting mode pulse parameters . . . . . 6 – 21
6.4.4.2 Adapting the piercing mode pulse parameters . . . . 6 – 23
6.4.4.3 Influencing factors in pulsed mode . . . . . . . . . . . . 6 – 23
6.4.4.4 Alternatives to pulsed cutting . . . . . . . . . . . . . . . . 6 – 23
6.4.4.5 Programming for pulsed contours . . . . . . . . . . . . . 6 – 24
6.4.4.6 Background information . . . . . . . . . . . . . . . . . . . . 6 – 27
6.5 Oxide-free cutting of rust and acid-resistant steel. 6 – 28
6.5.1 Cutting parameters for rust and acid-resistant steel . . 6 – 29
6.5.2 Rust and acid-resistant steel with protective film . . . . 6 – 29
6.6 Oxide-free cutting of aluminum alloys . . . . . . . . . . 6 – 31
6.7 Machining diverse materials . . . . . . . . . . . . . . . . . . 6 – 32
6.8 Plasma cut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 35
6.8.1 Practical applications . . . . . . . . . . . . . . . . . . . . . . . 6 – 36
6.8.2 Cutting parameters for custom sheets . . . . . . . . . . . 6 – 37
6.8.3 Plasma initial cut type in rust and acid-resistant steel,
15/20 mm thick . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 39
6.8.3.1 Partial plasma cut for sheet thicknesses up to 2 mm 6 – 40
6.8.4 Time comparison between quality and plasma cut . . . 6 – 41

Laser
Table of contents
6.9 Engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 43
6.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 43
6.9.2 Assessing an engraving . . . . . . . . . . . . . . . . . . . . . . 6 – 45
6.10 Machining with process macros . . . . . . . . . . . . . . . 6 – 46
6.10.1 Process macro 2 for the initial cut. . . . . . . . . . . . . . . 6 – 48
6.10.2 Example with process macros . . . . . . . . . . . . . . . . . 6 – 49
6.11 Piercing method . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 50
6.11.1 Conventional, pulsed piercing (without monitoring) . . 6 – 51
6.11.2 CPP(Controlled Pulsed Piercing) . . . . . . . . . . . . . . . . 6 – 52
6.11.2.1 Sequence for a CPP piercing . . . . . . . . . . . . . . . . . 6 – 54
6.11.3 Normal CW piercing . . . . . . . . . . . . . . . . . . . . . . . . 6 – 56
6.11.4 Pre-piercing CW . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 56
6.11.5 Pre-piercing CPP. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 58
6.12 Microjoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 59
6.12.1 Set microjoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 62
6.12.2 Microjoint welding . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 63
6.12.3 Alternatives to microjoints . . . . . . . . . . . . . . . . . . . . 6 – 64
6.13 Machining corners. . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 65
6.13.1 Machining corners with corner tolerance . . . . . . . . . . 6 – 65
6.13.2 Pointed corners in thick sheets
(with Dwell time parameter) . . . . . . . . . . . . . . . . . . 6 – 66
6.14 Support grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.14.1 Standard support grid . . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.14.1.1 Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.14.1.2 Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.14.2 Support grid for thin sheets . . . . . . . . . . . . . . . . . . . 6 – 68
6.14.2.1 Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 68
6.14.2.2 Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 68
6.14.3 Materials for support grids . . . . . . . . . . . . . . . . . . . . 6 – 69
6.15 Low-staff production. . . . . . . . . . . . . . . . . . . . . . . . 6 – 71
6.15.1 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 71

Laser
Table of contents
7 Materials
7.1 Material properties . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

7.1.1 alloy constituents, . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.1.2 microstructure, . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.3 Material surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.3.1 Positive effects . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.3.2 Negative effects . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.3.3 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.2 beam reflection, . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3 thermal conductivity, . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.4 Heat-affected zone . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
7.5 Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8

Laser
Table of contents
8 High-dynamic cutting

8.1.1 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.1.2 Part programming . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.2 Optimum parts programming . . . . . . . . . . . . . . . . . 8–3
8.2.1 Initial cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
8.2.1.1 Machining without initial cuts . . . . . . . . . . . . . . . . 8–3
8.2.1.2 Machining with initial cut . . . . . . . . . . . . . . . . . . . 8–3
8.2.1.3 Initial cut type . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.2.1.4 Initial cut point . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.2.2 Direction of rotation and cutting sequence in the part . 8–6
8.2.3 Positioning in Bysoft . . . . . . . . . . . . . . . . . . . . . . . . 8–7
8.2.4 Positioning the machine axes . . . . . . . . . . . . . . . . . . 8–8
8.2.5 Hole patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
8.2.6 Thin sheet machining using scanning . . . . . . . . . . . . 8–9
8.2.6.1 Schematic representation of the machining
sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
8.2.6.2 Machining characteristics for scanning . . . . . . . . . . 8 – 10
8.2.6.3 Machining example . . . . . . . . . . . . . . . . . . . . . . . 8 – 11
8.2.7 Erect parts after machining . . . . . . . . . . . . . . . . . . . 8 – 12
8.2.8 Thin sheet grids . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 13
8.2.9 Part machining sequence. . . . . . . . . . . . . . . . . . . . . 8 – 13
8.2.10 Warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 14
8.2.11 Pointed corners in thick sheets with loops . . . . . . . . . 8 – 14
8.3 Cutting parameters . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 15
8.4 Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 16
8.5 Quality of the main sheets . . . . . . . . . . . . . . . . . . . 8 – 17

Laser
Table of contents
9 Tube processing

9.2 Reducing the heat . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
9.3 Adjustment of cutting parameters . . . . . . . . . . . . . 9–6
9.4 Machining square and rectangular tubes . . . . . . . . 9–7
9.5 Quality of tubes and precision . . . . . . . . . . . . . . . . 9–8

Laser
Table of contents
10 Repositioning machines
10.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 10 – 3

10.2 Creating the cutting plan . . . . . . . . . . . . . . . . . . . . 10 – 4
10.3 Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 6

Laser
Table of contents
11 Cut evaluation

11.2 Cutting with oxygen (O2) . . . . . . . . . . . . . . . . . . . . 11 – 4
11.2.1 Structural steel 37-2, 4 mm thick . . . . . . . . . . . . . . 11 – 4
11.2.2 Structural steel 37-2, 10 mm thick . . . . . . . . . . . . . 11 – 6
11.2.3 Structural steel, 15 mm thick. . . . . . . . . . . . . . . . . . 11 – 9
11.2.4 Structural steel RAEX 420 Laser, 20 mm thick . . . . . . 11 – 10
11.2.5 Rust and acid-resistant steel 1.4301, 6 mm thick . . . . 11 – 12
11.3 Cutting with nitrogen (N2) . . . . . . . . . . . . . . . . . . . 11 – 13
11.3.1 Structural steel, hot galvanized, 2 mm thick . . . . . . . 11 – 13
11.3.4 Rust and acid-resistant steel 1.4301, 10 mm thick . . . 11 – 17
11.3.6 Aluminum AlMg3, 3 mm thick . . . . . . . . . . . . . . . . . 11 – 22
11.3.7 Aluminum AlMg3, 12 mm thick . . . . . . . . . . . . . . . . 11 – 24
11.3.8 Brass, 5 mm thick . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 26
11.3.9 Copper, 3 mm thick . . . . . . . . . . . . . . . . . . . . . . . . 11 – 27
11.3.10 Titanium, 3 mm thick . . . . . . . . . . . . . . . . . . . . . . . 11 – 27
11.4 Cutting with argon (Ar) . . . . . . . . . . . . . . . . . . . . . 11 – 28
11.4.1 Titanium, 3 mm thick . . . . . . . . . . . . . . . . . . . . . . . 11 – 28
11.5 Piercing with oxygen (O2) . . . . . . . . . . . . . . . . . . . 11 – 29
11.6 Piercing with nitrogen (N2) . . . . . . . . . . . . . . . . . . 11 – 30
11.6.3 Aluminum AlMg3, 12 mm thick . . . . . . . . . . . . . . . . 11 – 33
11.7 Quality of cut edges . . . . . . . . . . . . . . . . . . . . . . . . 11 – 34

Laser
Table of contents
12 Fault finding

12.2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 4
12.3 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 5
12.4 Beam guidance system . . . . . . . . . . . . . . . . . . . . . . 12 – 6
12.5 Laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 7

Laser

Laser
Chapter 1
1 Definitions and ranges
This chapter provides important information needed to ensure a safe cut-

ting process.

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Definitions and ranges Laser

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Laser Definitions and ranges
1.1 Definitions
1.1.1 Part area
The area of a geometric part is defined on the basis of the following crite-
ria:
Part area A = Area within a closed outer contour. Bores, slots and
openings are subtracted.
Fig. 1.1-1 Calculating a part area
2
A
3
Element Dimension Area
1 Square 100 x 100 mm 10 000 mm2
2 bore ∅20 mm -314 mm2
3 Rectangular 110 x 20 mm -314 mm2
4 bore ∅20 mm -2 200 mm2
A Part area 7 172 mm2

= 71.72 cm2

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Fig. 1.1-2 Examples of part areas
A Part area

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1.1.2 Parts size
Tab. 1.1-1 Defining the parts size as a function of sheet thickness
Sheet thick- Parts size

ness
in [mm] Small parts Medium parts Large parts
Part area Part area Part area
in [cm2] in [cm2] in [cm2]
0,5 ... 1,9 ≤ 10 cm2 10 ... 90 cm2 ≥ 90 cm2

2,0 ... 3,9 ≤ 20 cm2 20 ... 180 cm2 ≥ 180 cm2
4,0 ... 7,9 ≤ 40 cm2 40 ... 360 cm2 ≥ 360 cm2
8,0 ... 11,9 ≤ 75 cm2 75 ... 675 cm2 ≥ 675 cm2
12,0 ... 14,9 ≤ 100 cm2 100 ... 900 cm2 ≥ 900 cm2
15,0 ... 20,0 ≤ 150 cm2 150 ... 1 350 cm2 ≥ 1 350 cm2

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1.2 Ranges
1.2.1 Maximum cuttable sheet thicknesses
The following maximum sheet thicknesses can be cut given the informa-
tion provided in this chapter.
Tab. 1.2-1 Max. cuttable sheet thicknesses relating to material and laser module in use
Material Laser module
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Structural steel 15 mm 20 mm 25 mma) 25 mma) 25 mm
Rust and acid- 8 mm 12 mm 20 mma) 20 mma) 25 mm

resistant steel
Aluminum 6 mm 8 mm 12 mm 12 mm 15 mm
a) Restrictions may apply depending on machine type

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1.2.2 Minimum distance from sheet edge
The minimum distance from the sheet edge is 10 mm for a reliable cutting
process.
Fig. 1.2-1 Distance from sheet edge
10 mm
B
10 mm
10 mm 10 mm
A
During high-dynamic cutting1), the main sheet must be clamped. This re-
duces the usable surface by 40 mm. See section 8 ›High-dynamic cutting‹
Fig. 1.2-2 Distance from sheet edge during high-dynamic cutting

10 mm
B
10 mm
50 mm 10 mm
A
A Sheet
B Cutting plan
1) Only available with Byspeed machine type.

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1.2.3 Smallest cuttable bores
Small bores are pulsed in relation to the sheet thickness or cut with a pro-
cess macro. The Technology wizard carries out the exact assignment of
the best technology in Bysoft.
Tab. 1.2-2 Smallest cuttable bore
Sheet thickness Smallest cuttable bore
Maximum cuttable sheet thickness ac- 1 x sheet thickness

cord. to Tab. 1.2-1
All other sheet thicknesses 0,5 x sheet thickness
Parts quality may suffer or parts may be rejected if hole diame-

ters are less than the minimum hole diameters.

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1.2.4 Joint width / minimum joint width
Hole distances, opening-outer contour distance and distances between

contours are generally known as joint width. The smallest distance within
a part is known as the minimum joint width.
Fig. 1.2-3 Examples of joint widths
A
A
A Joint width
B Minimum joint width
In order to facilitate optimum production, the joint widths should be above

the minimum joint widths.
Tab. 1.2-3 Minimum joint width in relation to sheet thickness
Sheet Sheet thickness

thickness ... 3 mm 4 mm and above
Minimum joint width 3 mm min. sheet thickness
Parts quality may suffer or parts may be rejected if joint widths

are less than the minimum joint widths.

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1.2.5 Parts distance
The minimum distance between two parts is known as the parts distance.
Initial cuts outside of the contour are integral to the part.
The minimum parts distance for a reliable process is 10 mm (see Tab. 1.2-
4). This applies to other parts as well as the sheet edge.
Fig. 1.2-4 Parts distance examples
B
A
B
A Parts distance in x-direction

B Parts distance in y-direction
In order to facilitate optimum production, the parts distance should be

above the minimum parts distance.

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Tab. 1.2-4 Minimum parts distance with respect to sheet thickness
Material Cutting Sheet thickness

gas
... 10 mm 10 mm &
above
Structural steel Oxygen min. 10 mm min. sheet thick-

O2 ness
Rust and acid-resistant Nitrogen min. 10 mm min. 10 mm

steel N2
Aluminum min. 10 mm min. 10 mm
Structural steel min. 10 mm Not possible
Parts quality may be poor or the parts may be rejected if the

parts distance is not above the minimum parts distance.

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1.2.6 Hole patterns
Large parts can partially overheat if tightly-spaced hole patterns are cut.
The same rules and definitions apply for hole patterns as for the corre-
sponding individual part.
Fig. 1.2-5 Example of a hole pattern

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1.3 Achievable precision and quality
1.3.1 Parts precision
The tables below are based on the DIN 2310 Thermal cutting standard,
which has been extended for laser cutting.
The given tolerances are empirical values for laser flame cutting and laser
fusion cutting.
Tab. 1.3-1 Parts precision
Sheet Part length

thickness in [mm]
in [mm]
0 ... 10 10 ... 100 100 ... 300 300 ... 1 000
0,5 ... 2,9 ±0.10 mm ±0.10 mm ±0.20 mm ±0.25 mm

3 ... 5,9 ±0.20 mm ±0.20 mm ±0.20 mm ±0.25 mm
6 ... 9,9 ±0.20 mm ±0.20 mm ±0.20 mm ±0.30 mm
10 ... 14,9 ±0.25 mm ±0.25 mm ±0.30 mm ±0.30 mm
15 ... 19,9 ±0.30 mm ±0.30 mm ±0.30 mm ±0.30 mm
20 ... 25 ±0.35 mm ±0.35 mm ±0.35 mm ±0.40 mm
Sheet Part length

thickness in [mm]
in [mm]
1 000 ... 2 000 2 000 ... 3 000 3 000 ... 4 000
0,5 ... 2,9 ±0.30 mm ±0.40 mm ±0.50 mm

3 ... 5,9 ±0.40 mm ±0.50 mm ±0.60 mm
6 ... 9,9 ±0.40 mm ±0.50 mm ±0.60 mm
10 ... 14,9 ±0.40 mm ±0.60 mm ±0.80 mm
15 ... 19,9 ±0.50 mm ±0.60 mm ±0.80 mm
20 ... 25 ±0.60 mm ±0.70 mm ±1.00 mm

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The following conditions must be met in order to achieve the tolerances in

Tab. 1.3-1 for all parts:
Optimized cutting results, in particular tool compensation (generally the
default parameters)
When measuring parts, the evenness must be identical to the cutting
situation.
The internal stress of the main sheet is not taken into consideration in
the tables. Warping has a negative effect on the results.
The roughness must not influence the measurement.
Measurements may not be performed at the starting point of the con-
tour.
The relevant measurements may only be performed on parts with bare
edges.
Good system condition including all optical elements
Measurement and analysis procedure to VDI/DGQ 3441
Strong heating of the main sheet during cutting has a negative effect on
precision.
The mechanical precision of the laser cutting machines is much

greater than the precision of the parts (see Product descrip-
tion).

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1.3.2 Quality of the cut edge
Tab. 1.3-2 Structural steel cut with oxygen
Cut edge Laser module
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Oxidized cut edge burr-free. The layer of oxide 0,5 ... 10 mm 0,5 ... 15 mm 0,5 ... 15 mm 0,5 ... 15 mm 0,5 ... 15 mm
must be removed before subsequent surface
treatment (e.g. powder coating, varnishing,
etc.).
Oxidized cut edge burr-free. The layer of oxide 12 ... 15 mm 20 mm 20 ... 25 mm 20 ... 25 mm 20 ... 25 mm
must be removed before subsequent surface
treatment (e.g. powder coating, varnishing,
etc.).
The main sheet may overheat when cutting small
parts or several cut-outs

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Tab. 1.3-3 Structural steel cut with oxygen, quality cut
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Oxide-free cut edge, burr-free 0,5 ... 3 mm 0,5 ... 4 mm 0,5 ... 5 mm 0,5 ... 5 mm 0,5 ... 5 mm
Oxide-free cut edge. Burr formation possible on 4 mm 5 ... 6 mm 6 ... 8 mm 6 ... 10 mm 6 ... 12 mm
the lower face of the sheet
Tab. 1.3-4 Structural steel cut with oxygen, plasma cut
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Oxide-free cut edge with increased coarseness; ⎯ ⎯ 0,5 ... 1,5 mm 0,5 ... 2 mm ⎯
fine beads may form on lower face of sheet
Tab. 1.3-5 Rust and acid-resistant steel cut with nitrogen, quality cut
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Oxide-free cut edge, burr-free 0,5 ... 4 mm 0,5 ... 6 mm 0,5 ... 8 mm 0,5 ... 8 mm 0,5 ... 10 mm
Oxide-free cut face. Burr formation possible on 5 ... 8 mm 8 ... 10 mm 10 ... 12 mm 10 ... 12 mm 12 ... 15 mm

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Tab. 1.3-6 Rust and acid-resistant steel cut with nitrogen, plasma cut
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Oxide-free cut edge with increased coarseness; ⎯ ⎯ 0,5 ... 1,5 mm 0,5 ... 2 mm ⎯
fine beads may form on lower face of sheet
Oxide-free cut edge with increased coarseness; ⎯ ⎯ 15 ... 20 mm 15 ... 20 mm 20 ... 25 mm

beads may form on lower face of sheet
Tab. 1.3-7 Aluminum cut with nitrogen
2 200 W 3 000 W 4 400 W 5 200 W 6 000 W
Oxide-free cut edge, burr-free 0,5 ... 2.5 mm 0,5 ... 3 mm 0,5 ... 3 mm 0,5 ... 3 mm 0,5 ... 3 mm
Oxide-free cut edge. Burr formation possible on 3 ... 6 mm 4 ... 8 mm 4 ... 12 mm 4 ... 12 mm 4 ... 15 mm

ST_Laser_Kap01.fm

ST_Laser_Kap01.fm
Laser
Chapter 2
2 The laser cutting process
This chapter provides information about the cutting procedures that can
be used with the laser cutting machine.

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The laser cutting process Laser

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Laser The laser cutting process
2.1 Laser cutting areas
In principle, laser cutting can be divided into three areas.
Fig. 2.1-1 The laser cutting process
Laser cutting
Laser Laser
fusion cutting gas cutting Laser
sublimation cutting
(Cutting gas N2) (Cutting gas: O2)
Laser
plasma cutting
(Cutting gas N2)

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2.1.1 Laser fusion cutting
During fusion cutting, the work piece is melted locally and the melt is
blown out by a gas jet (nitrogen N2). The material is only transported in
the liquid phase, hence the term fusion cutting.
Fig. 2.1-2 Fusion cutting
Approximate position of the focal point
Characteristics:
Cutting gas: Nitrogen (N2) or argon

Laser power: 80 ... 100% of maximum power
Gas pressure: 10 ... 20 bar
Focal position: Approximately on the lower face of the sheet
A very pure, inert cutting gas is supplied to the laser beam, which ejects
the melted material from the cutting gap while itself taking no part in the
cutting process.
Laser fusion cutting is suitable for manufacturing oxide-free cut edges in
ferrous materials.

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2.1.2 Plasma cutting
Plasma cutting falls into the laser fusion cutting category. By altering the
cutting parameters, a bright light (similar to an arc) can be generated.
Using this method it is possible to cut faster up to a sheet thickness of
1.5 mm and to cut sheet thicknesses which would not otherwise be possi-
ble (rust- & acid-resistant steel, 15 ... 20 mm thick).
Fig. 2.1-3 Plasma cutting

Rust and acid-resistant Sheet thickness up to 1.5 mm
steel, thickness 15 ... 20 mm
Characteristics:
Bright light in the cutting gap during cutting.
Cutting gas: Nitrogen N2

Feed rate: Up to 40% faster than for normal laser fusion
cutting
Laser power: Mostly maximum power
Cut quality: Increased roughness (plasma cut)
Cut monitoring with Cut Control not possible.
An oxide-free cut edge is generated using plasma cutting.

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2.1.3 Laser gas cutting
Laser gas cutting differs from laser fusion cutting by the use of oxygen as
cutting gas. The interaction of oxygen with the heated metal causes a re-
action that heats the material still further.
Because of this effect speeds can be achieved when cutting structural
steel that are much greater than for fusion cutting in sheet thicknesses
from approx. 6 mm upwards.
Fig. 2.1-4 Gas cutting
Characteristics:
Cutting gas: Oxygen O2

Laser power: 25 ... 80% of maximum power
Gas pressure: 0,5 ... 5 bar
Focal position: Approximately on the upper face of the sheet
Oxygen laser cutting is critical when cutting fine contours and acute ge-
ometries (risk of burn-off). In pulsed mode, the heat input can be limited.

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2.1.4 Laser sublimation cutting
With laser sublimation cutting, the material is vaporized directly in the cut,
without a liquid phase.
Laser sublimations cutting is not used in Bystronic laser cutting

machines and is therefore only mentioned here for the sake of
comprehensiveness.

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2.2 Cutting process
By machining process is meant the interaction between the laser beam,

cutting gas and workpiece.
Fig. 2.2-1 Process parameters
Process parame-
ters of
Material Laser Cutting gas Axis movement
The zone in which this process occurs is known as the cutting front or cut
front. The laser power acting at the cutting front must heat the material to
the temperature required for phase transition of the material to smelt and
vapor.
The cutting front is a practically vertical surface that is heated and fused
by the absorbed laser power.
In laser flame cutting, this melt zone is heated up further by the flow of
oxygen blown into the cutting gap and reaches temperatures close to
the boiling point of the material. This causes strong vaporization, lead-
ing to ablation of the material. Simultaneously, the cutting gas ejects
molten material from the underside of the workpiece.
In fusion cutting the gas blows out the liquid material and protects the
cutting gap from oxidation.
The melt zone continues to move in the direction of cutting. This produces
a continuous cutting gap.
Many of the processes that play an important role in laser cutting take
place in this zone. An analysis of these processes allows important state-
ments on laser cutting. For example, it is possible to estimate cutting
speed and explain the formation of the characteristic striations.

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2.2.1 Gas parameters
Gas type
Gas purity
Gas pressure
Nozzle diameter
Nozzle geometry
The gas pressure and the nozzle geometry influence the cut face rough-
ness and the beading.
2.2.2 Cutting gas consumption
Cutting gas consumption depends on the nozzle diameter and the gas
pressure.
For low-pressure cutting applications gas pressure is up to 5 bar, for
high pressure cutting up to 20 bar.
The conventional cutting nozzle has a circular, conical orifice.
The distance between the nozzle orifice and the workpiece surface must
be as small as possible. The smaller this distance, the greater is the
proportion of the gas flow that actually enters the cut. Clearance dis-
tances typically range from 0.5 to 1.5 mm.

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ST_Laser_Kap02.fm
Laser
Chapter 3
3 Design and manufacture
This chapter describes the factors that influence the manufacturing pro-
cess.

ST_Laser_Kap03.fm
Design and manufacture Laser

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Laser Design and manufacture
3.1 Factors influencing the manufacturing pro-

cess
The following factors influence the manufacturing process:

The design options and limits
The working method and procedure
The interrelations between influence factors and parameters
Programming
Rules, advantages and hints
An optimum cutting result is already determined in the design process. It

is important that the designer is aware of the possibilities available in laser
cutting machine design. Only then can a component be designed for the
envisaged function and optimum production.
The person responsible for creating the cutting plans must have detailed
knowledge of the laser cutting machine. Ideally this person will have a lot
of experience with laser cutting machines. Only in this way can cutting
plans be optimally adapted to the laser cutting machine.
Practice has shown that the ideal location for the programming station is
close to the laser cutting machine. This guarantees a constant transfer of
knowledge between operator and programmer.
This chapter builds upon the basic knowledge of machine oper-

ating and programming. None of the basic functions are de-
scribed here.
Most descriptions are valid in general and are not restricted to
individual laser or machine types. The laser or machine type will
be mentioned in special cases.

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3.2 Material specification
If nothing to the contrary is stated, the cutting technology data refers to

the following materials:
Structural steel Thickness: 1 ... 15 mm St 37-2
Thickness: 16 ... 25 mm RAEX 420MC
Rust and acid-resistant steel (without a protective film) X5CrNi 18 9
Aluminum (without protective film) AlMg 3

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3.3 Design guidelines
When designing the parts to be cut the following guidelines should be ob-
served. This contributes to a substantial simplification of the manufactur-
ing process.
3.3.1 Sheet formats
The principal sheet formats are:

4 000 × 2 000 mm
4 000 × 1 500 mm
3 000 × 1 500 mm
2 500 × 1 250 mm
2 000 × 1 000 mm
3.3.2 Cutting gap width for laser cutting
The width of the cutting gap is a function of the focal length and the sheet
thickness. This cutting gap width cannot be altered.
However, using the tool radius cutting parameter, it can be compensated
(to guarantee dimensional accuracy).
Tab. 3.3-1 Guide values for cutting gap
Sheet thickness 1 3 5 8 12 15 20 25
in [mm]
Cutting gap in [mm] 0,15 0,20 0,25 0,40 0,50 0,50 0,60 0,65
It is possible to make only one cut in the width of the cutting

gap. This is used for strain relief cuts in the region of bends, for
example.

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3.3.3 Orthogonality of the cut face
When laser cutting, the cuting gap does not lie exactly square to the sheet
surface. Per 10 mm of sheet thickness, the cut edges are up to 0.1 mm
out of square.
Fig. 3.3-1 Out-of-square when cutting with oxygen (O2)

10 mm
10 mm
0,1 mm 0,1 mm
Fig. 3.3-2 Out-of-square when fusion cutting with nitrogen (N2)
0,1 mm
10 mm
The above geometries (Fig. 3.3-1 and Fig. 3.3-2) result from the selected
cutting process and cannot be altered.
The out-of-square is assessed according to DIN EN ISO 9013 (Classifica-
tion of thermal cuts).
As a rule, the out-of-square with laser cutting is significantly better than
with plasma cutting or thermal cutting.

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3.3.4 Roughness of the cut edges
The roughness of the cut edges increases with increasing material thick-
ness.
Generally, the roughness values of the DIN EN ISO 9013 tolerance
class 2 are reached with laser cutting.
An exception to this is the plasma cut in rust- and acid-resistant steel
(see Chapter6.8 ›Plasma cut‹).
Minor changes to the roughness of the cut face can be made using the
cutting parameters.
The following diagrams (Fig. 3.3-3, Fig. 3.3-4 and Fig. 3.3-5) show a
basic summary of the roughness values Rz. These values were calcu-
lated using a 4 400 W laser and may vary with other laser outputs.
Fig. 3.3-3 Guide values for rust and acid resistant steel with 4 400 W laser.
B E
Roughness Rz in [µm]
Sheet thickness [mm]
A Rust and acid-resistant steel, quality cut

B Rust and acid-resistant steel, plasma cut
C DIN EN ISO 9013 tolerance class 1
D DIN EN ISO 9013 tolerance class 2
E DIN EN ISO 9013 tolerance class 3

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Fig. 3.3-4 Guide values for structural steel with 4 400 W laser
E
B
D
A Structural steel, cutting gas nitrogen, N2

B Structural steel, cutting gas oxygen, O2
C DIN EN ISO 9013 tolerance class 1
D DIN EN ISO 9013 tolerance class 2
E DIN EN ISO 9013 tolerance class 3
Fig. 3.3-5 Guide values for aluminum with 4 400 W laser
E

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3.3.5 Contour radii
As a basic rule, contours and corners should be rounded. Avoid sharp con-
tours.
Advantages:
Shorter production times
Higher process reliability
Lower injury hazard
Improved visual impression
Tab. 3.3-2 Guide values for minimum radii at corners
Material Cutting Sheet thickness

gas in [mm]
10 ... 12
15 ... 18
5 ... 8
... 4
20
25
Structural steel Oxygen 0,8 1,0 1,5 2,0 3,0 4,0
O2
Rust and acid-resistant steel Nitrogen 0,8 1,2 2,0 3,0 4,0 5,0
Aluminum N2 0,8 1,5 2,5 4,0 — —
Structural steel 0,8 1,5 — — — —
The radii can be much greater than the minimum values in the table. If
the design does not allow for a radius, the corner can remain pointed. Ra-
dii smaller than 0.8 mm are more difficult to manufacture than pointed
corners.
The Bysoft Technology wizard provides a simple method of rounding cor-
ners.

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3.3.6 Sheet thickness
3.3.6.1 Select small sheet thicknesses
As far as the stability allows, the most effective material saving is

achieved by reducing the sheet thickness. Not only does this lead to less
weight, cutting and handling times are also shortened drastically.
However, the reduction in material thickness is only justified if it is not
achieved by additional manufacturing effort, such as welded reinforce-
ments.
3.3.6.2 Select equal sheet thicknesses
For single piece production it is expedient to fabricate all sheet compo-

nents of an assembly from as few different sheet thicknesses as possible.
The production times can be vastly reduced in this manner.

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3.3.7 Common separating cut
If a part is designed so that two neighboring edges can be processed with

a single cut, production time can be heavily shortened.
Fig. 3.3-6 Single piece production (each piece is cut separately)
Fig. 3.3-7 Production with common cut edges
Production with common cut edges is primarily suitable for all strip-
shaped parts from 500 mm long upwards. This can, in some cases, drasti-
cally reduce manufacturing time and minimize waste.
Various parts can be nested within each other so that they can all be man-
ufactured with common separating cuts.
Bysoft supports this procedure with simple functions.

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3.3.8 Hanging hole for the paint shop
A hole for hanging the workpiece can be of great assistance when paint-
ing. Make sure that these holes are made at the edge of the workpiece, so
that positioning pins can be easily used.
Min. hole diameter for lightweight parts: ∅4 mm

Min. hole diameter for heavy parts: ∅6 mm
3.3.9 Edge deformation
On the faces of sheets, deformation of the edges can occur due to com-
pression of the material during bending. A corner relief must therefore be
cut when:
The face needs to lie flat
A part is placed in a slot which is bent
Fig. 3.3-8 Corner reliefs

r
t
t
Sheet thickness Radius and corner relief

in [mm] in [mm]
r t
up to 3.0 8,0 1,0
3,0 ... 8,0 15,0 2,0
8,0 ... 15,0 20,0 4,0
15,0 ... 20,0 25,0 5,0

ST_Laser_Kap03.fm
3.3.10 Cut-outs
For opposing limbs, a relief is used in the corner. Radius r = sheet thick-
ness
Fig. 3.3-9 Corner relief for opposing limbs
r
For offset limbs, a relief is used in the corner. Radius r = sheet thickness
Fig. 3.3-10 Corner relief for offset limbs

r
Bysoft supports the use of cut-outs very simply.

ST_Laser_Kap03.fm
3.3.11 Tongues (bent parts only)
Incisions for tongues are always to be drawn as continuous lines with the
appropriate gap width. This ensures the simplest manufacture.
The tongue width should not be less than 50 mm. Gap width x = sheet
thickness
Fig. 3.3-11 Incisions for tongues
poorly designed
50 x
well designed

ST_Laser_Kap03.fm
3.3.12 Relief cuts
Holes and slots located too close to the bending line are deformed during
bending.
If the minimum side length cannot be achieved even with a smaller die, a
relief cut must be made.
Fig. 3.3-12 Stress relief cut
a Stress relief cut

b Bending line

ST_Laser_Kap03.fm
3.3.13 Intermittent limb
In profiles with an intermittent limb, the edges must be set back by at

least 1.5 × sheet thickness s.
Fig. 3.3-13 Set back edge in profiles with intermittent limbs
1,5 × s
s
Correct Incorrect

ST_Laser_Kap03.fm
3.3.14 Tongue and slot joints
Aligning, centering and tacking can be saved during welding by using con-
nectors. A welding gauge can also be dispensed with.
Ensure that the connector is manufactured with approx. 0.5 mm play, so
that individual parts can be easily fitted together.
Examples
Fig. 3.3-14 Straight joint
Fig. 3.3-15 Right-angled joint
Fig. 3.3-16 Multipart holder

ST_Laser_Kap03.fm
3.3.15 Marking similar parts
Marking is carried out using the engrave function. This is a simple way to
add part numbers, positioning aids and the such like to the parts in the
same work sequence as the laser cutting (also see section
6.9 ›Engraving‹).
Bysoft supports the programming of part numbers or consecutive num-
bers.
Examples
Fig. 3.3-17 Engraved part number
Laser engraved
Fig. 3.3-18 Engraved positioning aid
Laser engraved
The manufacturing process is prolonged by engraving markings.

ST_Laser_Kap03.fm
Laser
Chapter 4
4 Programming
This chapter provides information about technologies for piercings, initial

cuts and contours for various materials and lasers in use.

ST_Laser_Kap04.fm
Programming Laser

ST_Laser_Kap04.fm
Laser Programming
4.1 General instructions
Optimal programming substantially simplifies the cutting process and re-

duces manufacturing times while maintaining optimum part quality.
It is therefore important that the programmer is familiar with the laser
cutting machine and exchanges experience with the operating personnel.
Bysoft allows for optimum programming. Under certain cir-

cumstances, other software products do not make full use of
the potential of the laser cutting machine.

ST_Laser_Kap04.fm
Programming Laser
4.2 Technology wizard
The technology wizard provides support when programming parts. This

demands less detailed knowledge of the technology of the programmer.
An optimum cutting result is achieved substantially faster.
The following technologies are set up automatically for each laser, materi-
al, sheet thickness and geometry.
Fig. 4.2-1 Technologies which are automatically set
A Piercing type (CW / pulse)

B Initial cut type (straight / straight line with arc), initial cut length
and technology on the initial cut
C Technology set for contour (CW / pulse / process macro) as a func-
tion of the material, sheet thickness and the area to be cut
The cutting parameters of the laser cutting machine are opti-

mized for the wizard technologies. In general, the technology
wizard should always be used. This allows optimum exploitation
of the various options.

ST_Laser_Kap04.fm
Laser Programming
Fig. 4.2-2 Specify technology (in Bypart)
A Select material
B Select sheet thickness
C Select laser cutting machine
D Select technology table

ST_Laser_Kap04.fm
Programming Laser
4.2.1 Functionality examples
The following examples (Fig. 4.2-4, Fig. 4.2-5 and Fig. 4.2-6) illustrate
how the initial cuts and technologies are automatically selected in an opti-
mum way by the technology wizard for the same part, but with a different
material and sheet thickness.
Fig. 4.2-3 Part to be cut
A C B
25
8
∅14 8
60
A Hole ∅14 mm
B Square hole 8 x 8 mm
C Outer contour

ST_Laser_Kap04.fm
Laser Programming
Fig. 4.2-4 Technology for cutting structural steel, 12 mm thick
Material: Structural steel

Sheet thickness: 12 mm
Laser module: 5 200 W
Bore ∅14 mm
Initial cut type Straight line with arc
Initial cut length Start in center
Piercing Pulsed (CPP)
Cutting Process macro 1
Square hole 8 x 8 mm
Initial cut type Straight
Cutting Pulsed
Outer contour
Initial cut length 12 mm
Cutting CW

ST_Laser_Kap04.fm
Programming Laser
Fig. 4.2-5 Technology for cutting structural steel, 6 mm thick

Bore ∅14 mm
Cutting CW
Cutting Process macro 1
Outer contour
Cutting CW

ST_Laser_Kap04.fm
Laser Programming
Fig. 4.2-6 Technology for cutting rust- and acid-resistant steel, 4 mm thick
Material: Rust and acid-resistant steel

Cutting gas: Nitrogen N2
Bore ∅14 mm
Piercing CW
Cutting CW
Piercing CW
Cutting CW
Outer contour
Piercing CW
Cutting CW

ST_Laser_Kap04.fm
Programming Laser
4.2.2 Adaptations
For special applications it is possible to adapt the existing technology wiz-

ard or to program a new one.
The Bypart Online Help describes the procedure in detail.
4.2.3 Special features
When using the process macro Scanning1), the technology wizard must
remain inactivated.
1) See Chapter 8.2.6 ›Thin sheet machining using scanning‹ for further details.

ST_Laser_Kap04.fm
Laser Programming
4.2.4 Guidelines for piercings
Tab. 4.2-1 Various piercing types and their applications
Material Cutting gas Laser module
2 200 W 3 000 W 4 400 W / 5 200 W /

6 000 W
T in [mm] D≤T D>T D≤T D>T D≤T D>T
0,6 ... 1,5 Pulsed CW Pulsed CW Pulsed CW

Structural steel
2,0 ... 3,0 Pulsed CW Pulsed CW Pulsed CW

Oxygen
4,0 ... 8,0 O2 Pulsed CW Pulsed CW Pulsed Pulsed
10,0 ... 12,0 Pulsed CW Pulsed CW Pulsed Pulsed
15,0 ... 20,0 ⎯ ⎯ Pulsed CW Pulsed Pulsed
21,0 ... 25,0 ⎯ ⎯ ⎯ ⎯ Pulsed Pulsed
0,6 ... 1,5 CW CW CW CW CW CW

Structural steel

Nitrogen
5,0 ... 6,0 N2 ⎯ ⎯ CW CW CW CW
6,0 ... 8,0 ⎯ ⎯ ⎯ ⎯ CW CW

ST_Laser_Kap04.fm
Laser Programming
Material Cutting gas Laser module
2 200 W 3 000 W 4 400 W / 5 200 W /

6 000 W
T in [mm] D≤T D>T D≤T D>T D≤T D>T

acid-resistant

rust- and
Nitrogen
steel
8,0 ... 10,0 N2 ⎯ ⎯ CW CW CW CW
12,0 ... 14,0 ⎯ ⎯ ⎯ ⎯ CW CW
15,0 ... 20,0 ⎯ ⎯ ⎯ ⎯ Pulsed Pulsed

Aluminum

Nitrogen
6,0 ... 7,0 N2 ⎯ ⎯ CW CW CW CW
8,0 ... 12,0 ⎯ ⎯ ⎯ ⎯ Pulsed Pulsed
D = Bore diameter
T
T = Sheet thickness

ST_Laser_Kap04.fm
Laser Programming
4.2.5 Guidelines for initial cut types
If Bysoft is not employed for programming, the initial cuts must be defined as appropriate. The following table contains
base values from which Bysoft selects the initial cuts. However, the technology wizard specifies and optimizes the initial
cuts much more precisely.
Tab. 4.2-2 Various initial cut types and their applications
Material Technology on Cutting Initial cut type

the initial cut. gas
T in [mm] Directly on con- Initial cut length Length Radius

tour
1,0 ... 1,5 As contour Possible 3 mm

Structural steel
2,0 ... 3,0 As contour 5 mm
Oxygen
10,0 ... 15,0 As contour O2 12 mm 1 mm
16,0 ... 20,0 As contour 20 mm 1,5 mm
21,0 ... 25,0 Process macro 1 25 mm 3 mm

ST_Laser_Kap04.fm
Laser Programming


tour
1,0 ... 1,5 Pulsed 3 mm
2,0 ... 3,0 Pulsed 3 mm

Structural
Oxygen
steel
4,0 ... 8,0 Pulsed 4 mm
O2
10,0 ... 15,0 Pulsed 5 mm
16,0 ... 20,0 Pulsed 8 mm

Structural
Nitrogen
steel
2,0 ... 3,0 As contour 5 mm 1 mm
N2
4,0 ... 8,0 As contour 8 mm 1,5 mm

acid-resistant

rust- and
Nitrogen
steel
4,0 ... 6,0 As contour 8 mm 1,5 mm

N2
8,0 ... 10,0 As contour 12 mm 2 mm
12,0 Process macro 2 12 mm 3 mm

ST_Laser_Kap04.fm
Laser Programming


tour

Aluminum
Nitrogen
N2
4,0 ... 6,0 As contour 8 mm 1,5 mm
8,0 ... 12,0 Process macro 2 10 mm
T = Sheet thickness
T

ST_Laser_Kap04.fm
Laser Programming
4.2.6 Technology on the contour
Tab. 4.2-3 Technology on the contour, cutting gas oxygen
Material Cutting
gas D ≤ 0.8 × T 0.8 × T < D ≤ T T < D ≤ 1.5 × T 1.5 × T < D ≤ 3 × T D>3×T
T in [mm]
1,0 ... 1,5 Pulsed Pulsed Pulsed CW CW

Structural steel
2,0 ... 3,0 Pulsed Pulsed CW CW CW
Oxygen
4,0 ... 8,0 Pulsed Pulsed Process macro 1 CW CW
O2
10,0 ... 15,0 Pulsed Process macro 1 Process macro 1 Process macro 1 CW
D = Bore diameter
T
T = Sheet thickness

ST_Laser_Kap04.fm
Laser Programming
Tab. 4.2-4 Technology on the contour, cutting gas nitrogen
Material Cutting
gas D≤T T < D ≤ 1.5 × T 1.5 × T < D ≤ 3 × T D>3 × T
T in [mm]
1,0 ... 3,0 CW CW CW CW

Structural
Nitrogen
steel
4,0 ... 8,0 Process macro 1 CW CW CW
N2
1,0 ... 3,0 CW CW CW CW
acid-resistant
rust- and
Nitrogen
steel
N2
10,0 ... 12,0 Process macro 1 Process macro 1 CW CW
1,0 ... 3,0 CW CW CW CW

Aluminum
Nitrogen

N2
10,0 ... 12,0 Process macro 1 Process macro 1 CW CW
The Bysoft Technology wizard optimizes the piercing, initial cut and contour technology substantially finer than
given in Tab. 4.2-1 ... Tab. 4.2-4. Bysoft also differentiates between different machine types and sheet versions.

ST_Laser_Kap04.fm
Programming Laser
4.3 Piercing and initial cuts
The initial cuts should always reach their intended length and must be
placed accordingly.
Piercing causes the sheet to heat up very strongly. Strategic positioning of
piercing points and adequate length of initial cuts can help prevent heat
build-up.
An additional function is available on the 4 400 W, 5 200 W and 6 000 W
lasers: CPP (Controlled Pulsed Piercing). This reduces the heat input
greatly when piercing. See Chapter 6.11.2 ›CPP(Controlled Pulsed Pierc-
ing)‹.
At the limit thickness a radius initial cut is unavoidable for a uniform cut-
ting process.
Fig. 4.3-1 Poorly selected initial cuts
Heat build-up, possible deterioration of cut-

ting quality
Fig. 4.3-2 Well selected initial cuts with additional radius initial cut

ST_Laser_Kap04.fm
Laser Programming
4.3.1 Outer contour
The pierce hole is generally located outside of the contour (see Fig. 2 and
Fig. 3). The connecting line between the pierce and the contour is known
as the initial cutting pane or initial cut for short.
A change in direction of the laser beam between the end of the initial cut
and the contour, and the end of a cut, are recognized on the workpiece as
an irregularity in the cut edge.
Fig. 4.3-3 The initial cut is recognizable as an irregularity in the cut
The initial cut in the outer contour should therefore, if possible, be pro-
grammed as an extension of a geometry element (see Fig. 3).
Tab. 4.3-1 CW pierce hole
Parts requiring fin- Normal case Thick sheet option

ishing work
Fig. 1 Fig. 2 Fig. 3
CW pierce hole on con- CW pierce hole outside CW pierce hole outside

tour contour contour
Corner damaged Moving in contour in a
line.
Minor markings on
part

ST_Laser_Kap04.fm
Programming Laser
Various initial cut types can be employed within a part. This allows an
acute corner (A), for example, to be cut optimally.
Fig. 4.3-4 Various initial cuts
4.3.2 Inner contour (cut-outs)
With small inside contours it is important that the heat generated during
piercing can be dissipated before cutting begins.
The initial cutting pane may not be programmed in tight corners and
should be designed with the largest possible angle to the contour. This fa-
cilitates heat dissipation.
Fig. 4.3-5 Small inner contours
unsuitable suitable

ST_Laser_Kap04.fm
Laser Programming
4.4 Using process macros
The Bysoft Technology wizard assigns process macros automatically.
Tab. 4.4-1 Process macros
Process macro Description
1 Automatically used by the Technology wizard for small

contours. See Tab. 4.2-3 and Tab. 4.2-4
2 Automatically used by the Technology wizard for the ini-

tial cut in thick sheets . See Tab. 4.2-2
3 and 4 Available for customer-specific applications.
5 Reserved for vaporizing films (e.g. on rust and acid-re-

sistant steel).
The vaporizing is programmed in Bywork. The corre-
sponding cutting parameters are saved.
One or more contours which are assigned a process macro during pro-
gramming with Bysoft can be cut with other cutting parameters.
This has the advantage that difficult parts or sections of contour (e.g. gear
teeth) can be better optimized.
Fig. 4.4-1 Gear teeth cut with process macro
B
B
A Process macro 3
B CW

ST_Laser_Kap04.fm
Programming Laser
4.5 Radii on inner and outer contours
As a basic rule, you should avoid sharp contours when working with la-
sers. It is far simpler to cut a radius when changing direction.
Advantages:
corners do not burn,
time saving thanks to continuous process,
clean laser part,
Hazard of injury on part is smaller
Tab. 4.5-1 Minimum radii for outer and inner contours in [mm]
Material Cutting gas Sheet thickness

in [mm]
10 ... 12
15 ... 18
5 ... 8
... 4
20
25
Structural steel Oxygen O2 0,8 1,0 1,5 2,0 3,0 4,0
Structural steel Nitrogen N2 0,8 1,5 — — — —
Rust and acid-resis- Nitrogen N2 0,8 1,2 2,0 3,0 4,0 —

tant steel
Aluminum Nitrogen N2 0,8 1,5 2,5 — — —
Parts quality may suffer or parts may be rejected if radii are less
than the minimum radii.

ST_Laser_Kap04.fm
Laser Programming
4.6 Cutting-time calculation
The result of the cutting-time calculation is only a rough guide to the ex-
pected process time on the laser cutting machine. The effective process
time can differ significantly from this however.
The result from the cutting-time calculation must not be used

as a basis for quotations.

ST_Laser_Kap04.fm
Programming Laser

ST_Laser_Kap04.fm
Laser
Chapter 5
5 Cutting parameters
This chapter describes the procedure for the optimization of cutting pa-
rameters.

ST_Laser_Kap05.fm
Cutting parameters Laser

ST_Laser_Kap05.fm
Laser Cutting parameters
The cutting parameters for the permitted materials and cuttable sheet
thicknesses are provided.
The default parameters are given for metric sheet thicknesses. Countries
using different dimensional units (e.g. inches, Gauge No.) must use the
next closest metric cutting parameters. See section 5.5 ›Cutting parame-
ters for different dimensional units‹
The cutting parameters assume a minimum radius for each geometry (see
section 3.3.5 ›Contour radii‹). Parts quality may suffer or parts may be re-
jected if parts have a smaller radius.
The parameters for CPP piercing must be adjusted to suit the individual
sheet qualities.

ST_Laser_Kap05.fm
Before one can modify the cutting parameters correctly, it is very impor-
tant to know the following:
how the part is programmed
which technology is being used
The following example shows the technologies which are automatically se-
lected by the Technology wizard.
Fig. 5.1-1 Example: Structural steel, 8 mm thick
A Text Engraving
B Hole ∅4 mm Pulsed piercing
Pulsed cutting
C Longhole CW piercing
Cut with process macro 1
D Gear teeth CW piercing
Cut with process macro 1
E Outer contour CW piercing
CW cutting

ST_Laser_Kap05.fm
It is important that during cutting you closely note the operations for
which a parameter needs to be edited.
Normally, only very few parameters should need editing. Below are some
examples of how to quickly and purposefully achieve the optimum results.
Tab. 5.1-1 Cutting operations with the corresponding parameters
Cutting operation Parameter concerned
CW piercing CW piercing mode
Piercing time continuous wave mode
Laser power, piercing
Gas pressure CW piercing
Nozzle clearance height for piercing
Lead-in Acceleration factor for initial cut
Gas ramp, CW piercing/cutting
Possibly all CW parameters of process macro 2

(with thick sheets)
Outer contour Feed, continuous wave mode
Laser power, cutting
Gas pressure CW cutting
Nozzle type
Nozzle clearance height for cutting

ST_Laser_Kap05.fm
5.2 Adapting cutting parameters
Cutting parameters are scalable values with a direct influence on the cut-
ting process. The original cutting parameters are optimized for maximum
process reliability.
A set of cutting parameters is supplied with every laser cutting machine.
They are optimized to cut certain materials. Nevertheless, it is possible
that the parameters deliver unsatisfactory cutting results. Below, the re-
quirements and the procedure for obtaining better cutting results in such
cases are described.
For laser cutting there are numerous parameter that in part also exert a
mutual influence. Here, the five principal parameters with which the cut
quality can be optimized are listed:
Focal position
Laser power
Gas pressure
Feed rate
Nozzle distance
The adaptations are only valid for simple contours such as straight lines.
The cutting quality in a straight line cut-out only is evaluated

(directions x+, x-, y+ and y-). Interpolated cutting directions,
such as radii, diagonal cuts or initial cuts, for example, are not
taken into consideration.

ST_Laser_Kap05.fm
5.2.1 Reasons for parameter adaptations
Different material composition

Tolerance deviations in sheet thickness
Varying surface finish qualities
Large temperature differences of the materials used
(reference temperature = +20 °C)
5.2.2 Requirements for parameter adaptations
The following requirements must be fulfilled in order to achieve good cut

quality by adapting the principal parameters:
The laser cutting machine and the laser source must be in perfect con-
dition.
Lens in cutting head must be free of faults (see chapter Operating in-
structions).
The cutting head and the nozzle must correspond to the data in the re-
spective cutting parameters.
Avoid overwriting the original cutting parameters!

The edited parameters can be saved respectively with a new
material designation or new additional information.
Only use original nozzles and lenses.
After adapting a parameter it is recommended to print it and

store it in a folder using the Paramview application in the
Bysoft 6 Toolbox.

ST_Laser_Kap05.fm
5.3 Optimization of cutting parameters
5.3.1 Procedure
Before a new material is cut, a cutting test must be carried out. If the test
reveals problems with the cutting quality, these problems can be corrected
by adapting the original cutting parameter.
To facilitate the adaptation and testing of cutting parameters, cutting
plans are stored on the computer in the Acceptance folder, for the re-
spective laser type. Use the Ab_gross.lcc cutting plan for the test. This
takes all four cuts in x- and y-direction into consideration.
The following sequence for optimizing the cutting quality should be ad-
hered to:
1. Load the shuttle table with the main sheet to be cut and move it to
the machining position.
2. Select the WORK – Job list view on the user interface, create the
cutting job and assign the desired cutting parameters (see Operat-
ing instructions).
z Cutting plan Ab_gross.lcc or Ab_klein.lcc
z Cutting parameters based on the material to be cut
3. The evaluation of the cutting quality is based on the information giv-

en in chapter 11 ›Cut evaluation‹.
The further procedure for cutting optimization can be derived from
the possible causes and their remedies listed here. If a number of
options are given, the following sequence should be adhered to.
Sequence when specifying cutting parameters

Step Cutting with O2 Cutting with N2
1. Focal position Focal position
2. Laser power Feed rate ±10% OK
3. Gas pressure Laser power
4. Feed rate ±10% OK Gas pressure
5. Nozzle distance Nozzle distance

ST_Laser_Kap05.fm
4. The parameter values can be edited in the WORK – Parameters

view.
Edit only one cutting parameter at a time and then observe the ef-
fects (also see Chapter 11 ›Cut evaluation‹).
5. Activate the STOP ZERO stop button before cutting. Machining is

stopped at the origin of the cutting plan or at the origin of each indi-
vidual part.
A message appears in the status bar each time, which must be con-
firmed with CONT or STOP.
6. Repeat the cutting test with the edited parameters until a good cut
result is achieved.
7. Save the edited cutting parameters under a new file name (function:
Save as).
The edited parameters can be saved respectively with a new material
designation or new additional information.

ST_Laser_Kap05.fm
5.3.2 Focal position, cutting
The focal position or focal point denotes the smallest diameter of the laser
beam. At the focal point there is maximum power density.
The lens in the cutting head focuses the laser beam. Depending on the
material being cut, the focal point is located:
on the workpiece (focal position A)
in the workpiece (focal position B)
beneath the workpiece (focal position C)
Fig. 5.3-1 Focal position of the laser beam
Focal position A Focal position B Focal position C
The focal position depends essentially on the cutting gas used.
Cutting gas Laser cutting typea) Focal position
Oxygen Gas cutting Focal position in upper region

O2 of main sheet.
Focal position A
Nitrogen Fusion cutting Focal position in lower region

N2 of main sheet.
Focal position C
Compressed air Flame and fusion cutting Focal position approx. in center
Air of main sheet.
Focal position B
a) Information on the laser cutting methods can be found in section 2 ›The laser cutting
process‹.

ST_Laser_Kap05.fm
5.3.3 Altering the focal position
The focal position is altered as follows:
1. Open the WORK–Parameters view in the user interface.
2. Select the Cutting focal position parameter and enter a new value.
Input is in [mm].
z A higher numerical value displaces the focal position downwards.
z A lower numerical value displaces the focal position upwards.
z The numerical value 0 corresponds to the surface of the sheet (A).
Fig. 5.3-2 Alteration in the focal position
3. Confirm the input with OK.
The focal position alters with the condition of the lens. With a soiled or old
lens, the focal position moves upwards. This displacement can be up to
several millimeters, depending on the age or the degree of soiling. It is
therefore important to clean the lens regularly.
For the influence of focal position on various materials, see sec-

tion 11 ›Cut evaluation‹.

ST_Laser_Kap05.fm
5.3.4 Laser power, cutting
This parameter defines the laser power during cutting in continuous oper-
ation (CW).
The Laser power, cutting can be altered as follows:
2. Select the Laser power cutting parameter and enter a new value.
Input is in [W].
For the influence of laser power on various materials, see sec-


ST_Laser_Kap05.fm
5.3.5 Gas pressure, cutting
The gas pressure depends on the cutting gas used and the smallest nozzle
used.
Parameters Used for
Gas pressure, cutting, gas type 1 Cutting with O2

Maximum gas pressure 10 bar.
Gas pressure, cutting, gas type 2 Cutting with N2

Maximum gas pressure 24 bar.
Gas pressure, cutting, gas type 3 Cutting with compressed air (optional)
Maximum pressure 12 bar.
The gas pressure is altered as follows:
2. Select the appropriate parameter for the gas pressure (gas type 1,
gas type 2, or gas type 3) and enter a new value. Input is in [bar].
For oxygen (O2), a higher value produces a higher cutting tempera-
ture and a rougher cut surface.
For nitrogen (N2), the material is ejected better and cooled more.
For the influence of gas pressure on various materials, see sec-


ST_Laser_Kap05.fm
5.3.6 Feed rate, cutting
This parameter defines the feed rate during cutting in continuous opera-
tion (CW).
The Feed rate, cutting is a variable quantity and is dependent on other
factors.
Example:
Maximum Feed rate, cutting 6,0 m/min Corresponds to

(with reduced quality) 100%
Saved original parameter Feed rate, 5,4 m/min Corresponds to

cutting approx. 90%
Minimum cutting speed 4,2 m/min Corresponds to

approx. 70%
If the minimum cutting speed can no longer be achieved dur-

ing production, the laser cutting machine will need to be
checked by the manufacturer's service personnel.
The Feed rate, cutting can be altered as follows:
2. Select the cutting feed rate parameter and enter a new value. In-
put is in [mm/min].
By reducing the feed rate by 10 ... 20% the quality or process reliability
can be greatly improved in almost all cases.
For the influence of the cutting feed rate on various materials,

see section 11 ›Cut evaluation‹.

ST_Laser_Kap05.fm
5.3.7 Nozzle clearance height for cutting
This parameter defines the distance of the nozzle from the surface of the
workpiece during cutting.
The Nozzle clearance height for cutting can be altered as follows:
2. Select the Nozzle clearance height for cutting parameter and en-
ter a new value. Input is in [mm].
Nozzle distance Effect
<1 mm Wear and soiling of the nozzle increase
>1 mm reduced cutting quality

Lower nozzle heating for plasma cutting

ST_Laser_Kap05.fm
5.4 Cutting with laser source 5 200 W
5.4.1 Focal position and beam diameter
When altering the Beam diameter cutting parameter, the focal position is
also altered. The interaction of beam diameter and focal position can lead
to the focal positions no longer taking up their previous positions.
Calculation of the cutting parameters was based on an assumed focal po-
sition for structural steel of 0 (focal position on the sheet surface). The
other focal positions are acquired from the optimum beam diameter and
the thickness.
Fig. 5.4-1 Beam diameter 20 mm (cutting head 7.5″ )

ST_Laser_Kap05.fm
1. Alter beam diameter from 20 mm to 21 mm.
Fig. 5.4-2 Beam diameter 21 mm (cutting head 7.5″ )
z Displacement of focal position 1 mm downwards.

z The focal position in the cutting parameter stays the same.
2. Focal position required to position the focal point on the sheet sur-
face again for the altered beam diameter:
Focal position: -1 mm
Tab. 5.4-1 Displacing the focal position
Beam diameter Displacing the focal position

with
Before After Focal length 5.0″ Focal length 7.5″
20 mm 19 mm approx. 0.5 mm approx. 1 mm

upwards upwards
20 mm 21 mm approx. 0.5 mm approx. 1 mm

downwards downwards

ST_Laser_Kap05.fm
5.5 Cutting parameters for different dimensional

units
The default parameters are given for metric sheet thicknesses. Countries
using different dimensional units (e.g. inches, Gauge No.) must use the
next closest metric cutting parameters, as shown in Tab. 5.5-1.
Tab. 5.5-1 Cutting parameters to use for different dimensional units
Sheet thickness
in [mm] in [inches] in [Gauge No]
1,0 0,040 19
1,5 0,060 16
2,0 0,074 14
2,5 0,104 12
3,0 0,125 11
4,0 0,160 8
5,0 0,187 7
6,0 0,250 ⎯
8,0 0,312 ⎯
10,0 0,375 ⎯
12,0 0,500 ⎯
15,0 0,625 ⎯
20,0 0,750 ⎯
25,0 1,000 ⎯

ST_Laser_Kap05.fm
Laser
Chapter 6
6 Machining process
This chapter provides information on cutting with various materials. This

chapter also includes cutting parameter adjustments for complex contours
(such as acute-angled corners, radii, small contours, initial and end cuts,
bores, etc..).

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Machining process Laser

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Laser Machining process
To ensure a reliable cutting process, it must be ensured that no cut sheet

parts remain erect which could collide with the cutting head. This can be
ensured by using microjoints, welding points or by cutting inside parts.
During the laser cutting process, the sheet must not undergo deformation
or stand erect enough to produce a collision with the cutting head, bridge
or machine frame.

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6.2 Various technologies
Tab. 6.2-1 Operating modes and applications
Operating mode Usage Example
Continuous mode Low pressure cutting Structural steel cut with ox-
(CW) Normal cutting ygen (O2)
High-pressure cutting Aluminum cut with nitrogen

(N2)
Rust and acid-resistant steel
cut with Nitrogen N2
A relatively fine cut results
from continuous power op-
erating
Modulation (MOD) Cutting corners With modulation activated

Accelerating and braking the laser power is automati-
cally adjusted to the axes
speed.
This prevents corners from
getting burnt off.
Normal pulse (NP) Piercing Structural steel example:

Small contours Small piercings on contour
(after microjoint)
Small bores down to ∅1/2
sheet thickness
Fine contours
Normal pulse (NP) CPP (Controlled Pulsed Piercing in structural steel

Piercing) with oxygen O2
1 ... 25 mm
Only with laser sources Piercing in rust and acid-re-

4 400 W sistant steel
5 200 W 16 ... 25 mm
6 000 W Piercing in aluminum
8 ... 15 mm

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6.3 Cutting structural steel
Structural steel can be cut to good quality with oxygen (O2). The laser is
used in CW mode.
When laser cutting with oxygen the cut face is slightly oxidized. The high
pressure cutting method can be utilized for sheet thicknesses of up to
12 mm1), employing Nitrogen (N2) as the cutting gas. In this case, the cut
edges are oxide-free.
Complex contours and bores (where diameter is smaller than the sheet
thickness) are cut in pulsed mode with oxygen. This prevents burn-off on
sharp corners and thin joints.
The greater the carbon content of the steel, the greater the hardening
of the cut edge and the more that acute-angled corners are burned off.
Sheets with alloy content are more difficult to cut than sheets with
small content.
An oxidized or sand-blasted surface will produce a far poorer cut quali-
ty.
Color markings on the surface of the sheet have a negative effect on
the cutting result.
With sheet thicknesses above 12 mm good results are achieved with la-
ser sheets (e.g. Raex) and an oiled surface. This oil film reduces the ad-
hesion of the slag on the surface and assists cooling considerably. The
oil film is not detrimental to the cutting result.
Use only fully killed steel where possible. Soiling in unkilled steel has a
very negative effect on cutting results. Dressing rollers and inner stress
also influence the cutability.
1) Depends on the laser source output

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For smaller contours with sheet thicknesses of 15 and 20 mm we recom-

mend fine-grain steel, e.g.: RAEX 420 Laser from Rautaruukki Steelworks,
Raahe (corresponds to a QStE 420 TM in accordance with EN, DIN, SEW).
This steel is manufactured from a special smelt with a maximum silicon
content of 0.04% and a maximum carbon content of 0.012%. It has a
tensile strength of 490 ... 620 N/mm2.
No slag generation during laser cutting
No warping of cut parts
Best bending properties
Low spring-back
Good welding properties
This steel is available in thicknesses of up to 25 mm
When using St 52-3, poorer cutting results are achieved, because it tends
to sag and burr due to the viscous slag.
The following guidelines should observed for cutting structural steel with a
clean surface:
Si ≤ 0.04%: Preferred; very good laser workability

Si < 0.25%: May have slightly reduced cutting properties
Si > 0.25%: Steel of limited suitability for laser cutting and thus infe-
rior or irregular cutting results
Tolerance to DIN for steels up to St 52 is Si ≤0.55%. This infor-

mation is not precise enough for machining with laser.

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6.3.1 Machining large sheet thickness in structural steel
Large sheet thicknesses are defined as sheets with a thickness of

12 ... 25 mm.
When laser cutting with large sheet thicknesses, the main sheet warms up
strongly during piercing and cutting. This can result in overheating and
poor parts quality. The following chapters provide information about how
an overheating can be prevented.
6.3.1.1 piercing
Whenever possible CPP piercing should be used (see Chapter

6.11.2 ›CPP(Controlled Pulsed Piercing)‹).
If a part contains many piercings, we recommend you use pulsed pierc-
ing with CPP. This is programmed in the Bywork Bysoft module. All
piercing holes are firstly pulsed pre-cut for each part. Afterwards cut-
ting takes place.
This has the advantage of allowing the material around the piercing to
cool. This makes it significantly better to start moving for cutting the
edges.
If the laser cutting machines does not haveCPP, pre-cutting is also pos-
sible with a CW piercing.
Oiling the sheets is useful. This prevents piercing splashes from adher-
ing to the sheet surface.
An oiled sheet surface has a negative impact on the pre-cutting pro-
cess.
The Crossjet allows an oil mist to be sprayed. The oil mist is an air-oil
mixture. The oil mist cools the piercing point.
Piercing splashes can be blown away with the cross-blowing function.
This prevents the splashes from sticking to the main sheet.
6.3.1.2 Cutting
You should ensure that the temperature of the main sheet does not ex-
ceed 40 °C. Otherwise, chipping may occur on the cut edges. The follow-
ing chapters provide information about how this can be achieved.

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6.3.1.3 Large parts / large sheet thickness
In order to cut such parts with the necessary process reliability in produc-
tion, the following guidelines must be observed:
All acute angled contours must be given a radius.
See section 4.5 ›Radii on inner and outer contours‹
Smallest openings (bores, slots) 1.2 ... 1.5 × sheet thickness.
Minimum joint width 1.2 ... 1.5 × sheet thickness.
See section 1.2.4 ›Joint width / minimum joint width‹
Minimum part separation 1.0 ... 1.5 × sheet thickness, but at least
10 mm, in order to ensure reliable capacitive sensing.
See section 1.2.5 ›Parts distance‹
Initial cut length 1 × sheet thickness, but at least 10 mm.
See section 4.2.5 ›Guidelines for initial cut types‹
Heat-optimized cutting sequence within the part using following crite-
ria:
1. Engraving
2. Pulsed contours (smallest first)
3. Contours with process macro (smallest first)
4. Inner contours with CW (smallest first)
5. Outside contours with CW
The cutting sequence can be preset in Bysoft and is set automatically.
Heat-optimized nesting (cutting sequence of parts in the cutting plan).

This ensures good distribution of heat within the cutting plan. E.g, see
chapter 6.3.1.4 ›Example 1: Cutting in one pass‹
If these guidelines are not adhered to the result can be over-

heating of the main sheet.
The first signs of overheating are rough cut surfaces, burnt con-
tour cuts and melt not blown out (also see Fig. 11.2-14).

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6.3.1.4 Example 1: Cutting in one pass
When cutting in one pass, ensure the heat distribution using heat-opti-
mized nesting.
Fig. 6.3-1 Individual part
Material: RAEX 420 MC

Part dimensions: 850 × 850 mm
Panel dimension: 3 000 × 1 500 mm
Fig. 6.3-2 Cutting plan
A
4 2 6
1 5 3 C
A The numbers (1 ... 6) indicate the cutting sequence.

B Single part
C Sheet

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6.3.1.5 Example 2: Cutting in two passes
The complete cutting plan is divided into two new cutting plans. In the
first plan, only every second part is cut. See Fig. 6.3-5 and Fig. 6.3-6
Fig. 6.3-3 Single part
Material: RAEX 250

Part dimensions: x = 100 mm
y = 80 mm
Shape spacing: x = -18 mm
y = 17 mm
Panel dimension: x = 675 mm
y = 689 mm
Fig. 6.3-4 Complete cutting plan

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Fig. 6.3-5 Cutting plan, first pass
After the first pass, interrupt cutting until the temperature of the panel
drops below 40 °C. Only then can the remaining parts be cut (in the 2nd
cut).
Fig. 6.3-6 Cutting plan, second pass
Another cutting plan can be processed on the second shuttle ta-

ble to prevent a delay when cooling the main sheet. Afterwards,
perform a table interchange and cut the second pass.

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6.3.1.6 Example 3: Residual grid cut as heat separation
To prevent the applied heat from warming up the main sheet to strongly,
you can divided the sheet into segments using residual grid cuts. The re-
sidual grid cuts are programmed in Bywork are cut before the parts.
It is preferable to have the cutting sequence in two passes within the indi-
vidual segments. See section 6.3.1.5 ›Example 2: Cutting in two passes‹
Fig. 6.3-7 Single part
Material: RAEX 250

y = 80 mm
Shape spacing: x = -18 mm
y = 17 mm
y = 689 mm

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Fig. 6.3-8 Complete cutting plan with residual grid cut
A B C
A Segment 1
B Segment 2
C Segment 3
D Residual grid cut between segments
Fig. 6.3-9 Process segment in two passes
Segment, first pass Segment, second pass

ST_Laser_Kap06.fm
6.3.1.7 Unsuitable parts for production
These are mainly small parts with large sheet thicknesses (see
chapter1.1.2 ›Parts size‹).
However, special geometries can also present cutting problems.
Example:
Figure 1 without radii cannot be cut in this way
Figure 2 with radius= 2 mm can be cut as a single part with restrictions
Parts of such size with large sheet thicknesses are unsuitable for pro-
duction
Fig. 6.3-10 Unsuitable parts
Figure 1 Figure 2
Material: RAEX 250

y = 17 mm
y = 83 mm

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6.3.2 Cutting of structural steel with nitrogen (N2)
Structural steel is also cut using Nitrogen (N2) for the following reasons:
The oxide-free cutting edge enables an optimal adhesion of powder
coatings and varnishings on the cut edge. This is not guaranteed on an
oxidized cut edge with oxygen (O2).
Problem-free cutting of high-alloy steels, which cannot be cut at good
quality using oxygen.
Higher cutting speeds. Solids can be cut faster up to a thickness of
2 mm. Also see chapter 6.8 ›Plasma cut‹.
Reducing the heat input.
Fig. 6.3-11 Example: Gear teeth in structural steel, thickness 3 mm, cut using Nitrogen
Optimum cut quality due to strong cooling effect of nitrogen. The produc-
tion time is only 1/4 of the pulsed time using oxygen.
When using nitrogen (N2) gas consumption is substantially

higher than for oxygen (O2).

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6.4 Pulsed cutting
During pulsed cutting the laser is switched on and off at short intervals.
The advantage of this is that, on average, there is less heat input to the
material. This allows small bores and openings, as well as complex con-
tours, to be cut with good quality.
Because the cutting and piercing process is interrupted in the pulse pause,
the cutting and piercing speed is slower than for continuous CW cutting
and piercing.
Fig. 6.4-1 Sequence during pulsed cutting
A
B C D
A Laser power in [W]

B Pulse period
C Pulse pause
D Pulse width
E Pulse frequency in [Hz]
6.4.1 Pulsed cutting (application examples)
Holes and openings smaller than sheet thickness, e.g. a hole with
∅5 mm in a steel sheet, thickness 10 mm
Cutting points and corners without radii

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6.4.2 Pulsed piercing (application examples)
Piercing with lower heat input

Piercing without piercing crater
Piercing on the contour, so that inner part and outer part can be used
Tab. 6.4-1 Difference between pulsed and continuous cutting
Criterion Pulsed cutting or Continuous (CW) cut-

piercing ting
Cutting speed Low High
Heat input to the Low High

main sheet
Cut quality Rough, brown color Fine
Piercing Small, fine, as wide as cut Large, with crater

gap

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6.4.3 Recommended values
Tab. 6.4-2 Simple guide values for pulsed piercing
Parameters Guide value

1
Piercing time, [s] /2of panel width in seconds
pulsed mode
Nozzle clearance [mm] 1 ... 2 mm

height for pierc- for thinner material closer to 1 mm, for thicker
ing closer to 2 mm
Gas pressure, [bar] 2 bar, for nozzle diameters over 2.5 mm 1 bar is
pulsed piercing also permissible
Initial pulse fre- [Hz] Focal length 5.0″ 50 ... 300 Hz

quency, piercing
Focal length 7.5″ 10 ... 25 Hz
End pulse fre- [Hz] Focal length 5.0″ 150 ... 300 Hz (always
quency, piercing higher than the initial
pulse frequency)
Focal length 7.5″ 100 ... 150 Hz (always

higher than the initial
pulse frequency)
Pulse width [ms] Increases with sheet thickness from

1 000 ... 2 500 ms
Laser power, [W] Approximately the same or higher than normal

piercing piercing power

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Tab. 6.4-3 Simple guide values for pulsed cutting
Parameters Guide value
Feed, pulse mode [mm/min] Normal feed rate divided by the factor 10
(limit thickness 20 mm)
Nozzle clearance [mm] Same as for continuous cutting (CW)

height for cutting
Gas pressure, [bar] Same as for continuous cutting (CW)

pulsed cutting
Pulse frequency, [Hz] Decreasing strongly with increasing sheet

cutting thickness
Focal length 5.0″ Between

100 ... 400 Hz
Focal length 7.5″ Mostly below 100 Hz
Pulse width [ms] Increasing strongly with increasing sheet

thickness
Laser power, cut- [W] Higher than laser power for continuous cut-
ting ting
Tool radius, [mm] To start, the same as for continuous cut-

pulsed mode ting, adapt later
The standard parameters for pulsed cutting are optimized for

holes and openings of 1/2 sheet thickness (e.g. a hole with
∅5 mm in structural steel, thickness 10 mm).

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6.4.4 Parameter adaptations for complex contours
Beside normal pulsed applications such as small bores, there are more un-
usual applications, for example gears or ultra-precise joints. However,
these applications are very rare in the production of laser parts and are of
correspondingly little importance.
Examples:
Fig. 6.4-2 Gear teeth, structural steel, thickness 3 mm
Fig. 6.4-3 Fine joints in thick sheet, structural steel, thickness 10 mm

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6.4.4.1 Adapting the cutting mode pulse parameters
1. Reduction of feed rate
2. Reduction of pulse frequency
3. Varying the pulse width
All other parameters must need not normally be adapted.
Tab. 6.4-4 Example: Complex contour
Parameters Parameter value
Default Edited
Feed rate [mm/min] 180 45
Pulse frequency [Hz] 20 5
Pulse width [ms] 11 500 14 000

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Fig. 6.4-4 Cutting result with default parameters
Cut with default parameters

Fig. 6.4-5 Cutting result with edited parameters
Cut with edited parameters
feed rate Minus 40%

1
Pulse frequency /4 of default frequency
Pulse width Default value × 2.5
Laser performance From 60% to 100%

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6.4.4.2 Adapting the piercing mode pulse parameters
1. Increasing piercing time
2. Reducing the initial and/or final pulse frequency (reduction of heat

input)
3. In order to stop the piercing time becoming too long due to step 2,
the laser power can be increased at the same time.
4. Variation of pulse width.
6.4.4.3 Influencing factors in pulsed mode
Quality and surface of main sheet

Temperature of main sheet. Pulsing (piercing and cutting) can behave
differently with a strongly heated main sheet than a cold one.
Piercing no longer takes place with individual pulses but almost like an
explosion. The edge can burn out during cutting. To keep the tempera-
ture of the main sheet as low as possible, see the information in Chap-
ter 6.3.1 ›Machining large sheet thickness in structural steel‹.
6.4.4.4 Alternatives to pulsed cutting
Often, cutting can be done using nitrogen instead of pulsed cutting, up to

sheet thicknesses of 6 mm. See Chapter 6.3.2 ›Cutting of structural steel
with nitrogen (N2)‹.

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6.4.4.5 Programming for pulsed contours
Whether or not contours are cut pulsed or are pierced can be determined
in two ways:
Automatically with the Technology wizard. This contains the two most
important rules for machine which method is used to cut contours. It
also has the advantage of shortening the programming time.
Special areas of the outer contour (e.g. gears) are not au-
tomatically detected by the Technology wizard. In this case
the correct technology must be set manually.
Manual. The programmer selects the individual contours based on his

own experience cutting on the machine.
If only portions of the contour are cut pulsed, e.g. the teeth in the follow-
ing figures, the programming must be carried out so that there as few
changeover points as possible (A).
Fig. 6.4-6 Poor programming (two changeover points)
A
A
Two changeover points (A)

Normal — pulse — normal

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Fig. 6.4-7 Good programming (one changeover point)
One changeover point

Because of the optimum positioning of the initial cut, only one changeover
point from normal to pulsed cutting is necessary. This improves the part
quality.
Part programming has a great effect on good pulse results:
Pulsing should, where possible, be switched on after CW cutting (not
the other way round). This improves the transitions on the cut edge.
Changeover points from CW to pulse should be positioned so that the
changeover takes place at a change of direction or in a corner. Do not
changeover on straights or in curves. Changing over from one mode to
another causes a small irregularity.

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Fig. 6.4-8 Cutting in CW and pulsed mode
unsuitable suitable
B B
A
A A
B B
C C
A
C C
A A A A
B B B B
A Switchover point
B CW cutting
C pulsed cutting
The cutting sequence should be selected so that the complex

contours are always cut first on one part, i.e. the smallest first
(usually the pulsed ones).

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6.4.4.6 Background information
Special parameters
The modulation is switched off for pulsed cutting.
Hand-held controller
At low speeds the manual cut with display differences compared to a nor-
mal pulsed cut. In manual mode only feed rates with increments of
60 mm/min are considered. This means that the smallest possible feed
rate is 60 mm/min, then 120 mm/min, etc.
Cut evaluation
The second half of the cut edge often displays a brownish coloring. The
oxidation, which is responsible for the brown discoloration, is generated in
the pulse pause by the oxygen cooling (see Fig. 11.2-4).
Burning
If burning occurs at the end of the cut, setting an automatic microjoint or
programming an final cut outside the contour may help to alleviate this.
Fig. 6.4-9 Automatic microjoint or final cut
B
A A C
A
A Cut direction
B Automatic microjoint
C Final cut
Automatic microjoints do not require programming. These can be activat-

ed directly on the machine control unit. A final cut is programmed with
Bysoft.

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6.5 Oxide-free cutting of rust and acid-resistant

steel
The following points require attention when cutting rust and acid-resistant
steel.
Cutting with nitrogen to achieve oxide- and burr-free cut edges for
post-processing without with further treatment.
Employing high laser power and high pressure cutting in conjunction
with nitrogen, comparable or even higher cutting speeds can be
achieved than when cutting with oxygen depending on the sheet thick-
ness.
In order to cut rust and acid-resistant steel more than 5 mm thick burr-
free across the whole sheet using nitrogen, it is necessary to adjust the
focal position. By averaging out the focal position and reducing the
speed it is possible to cut clean cuts, albeit with slight burring.
With the Adaptive Optics 1 option it is not necessary to adjust the fo-
cal position manually.
An oiled sheet surface improves piercing without reducing the machin-
ing quality (see Fig. 11.6-2).
Whenever possible, CutControl should be employed. This increases the
process reliability and minimizes defective parts.
Substantially greater nozzle clearance height for piercing than for cut-
ting. A greater nozzle clearance height helps to prevent splashes on the
lens.
When cutting rust and acid-resistant steel, support grids of

the same material must be used.
Steel or copper grids can be used to prevent slag which forms
on the support points from melting into the cut part. These
will subsequently oxidize.
When cutting rust and acid-resistant steel on copper support
grids, ensure that these are first cleaned with an anti-rust
cleaner.

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6.5.1 Cutting parameters for rust and acid-resistant steel
An extremely large amount of alloyed stainless steels are available on the

market. The default parameters refer to the most common alloy (DIN
1.4301).
With the appropriate adaptation of the focal position, feed rate, la-
ser power and gas pressure, almost all stainless steels can be cut. To
begin with, the respective default parameters (DIN 1.4301) should be
used.
Adapt the cutting parameters based on the information given in section
5.3 ›Optimization of cutting parameters‹. Compare the cutting results
achieved with the figures in section 11 ›Cut evaluation‹.
6.5.2 Rust and acid-resistant steel with protective film
Protective films are adhered to the surface to protect brushed, polished or

refined surfaces with sheet thicknesses of up to 3 mm.
Important for a decisive role for laser cutting is how well the film adheres
to the surface. Poorly adhered films come lose from the main sheet due to
the pressure of the cutting gas, thus interrupting the cutting process.
Tab. 6.5-1 Cutting main sheets with protective films
Protective film status Measures
Protective film has poor ad- Remove the protective film and cut with the cut-
hesion ting parameters for rust and acid-resistant
steel.
The surface is however no longer protected.
Vaporize the protective film on the initial cut or

whole contour.
The programming takes place in Bywork under
post processor 2. Select process macro 5 for the
vaporization of the protective film.
The necessary cutting parameters are saved on
the laser cutting machine.
Protective film has good ad- Directly cut the main sheet with special cutting
hesion parameters (Add-on = plastic-film).
This is the quickest, most economical solution.

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The adhesive force of the protective film lessens over time.

Do not store main sheets with protective films for longer peri-
ods of time.
Do not store main sheets with special protective films for
longer periods of time.
Recommended protective films:

Laserguard 3100H5 and Laserquard 3100H3 Light produced by Nitto Den-
ko with the following properties good for laser cutting:
Very good adhesion during cutting. No need to vaporize protective film
beforehand.
Visually cleanly cut parts without black discoloration around edges.
No fraying of protective film around edges.
High tear strength when removing from sheet (especially after bending
process)1)
Minimal residual adhesive on the sheet
1) This is a very important property. Approx. 80% of parts cut with a laser are bent
afterwards.

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6.6 Oxide-free cutting of aluminum alloys
An extremely large amount of aluminum alloys are available on the mar-

ket. The default parameters refer to the most common alloy (DIN
3.3535), AlMg3. This alloy can also be bent well.
The cutting gas used is nitrogen (N2). Oxygen is also used for piercing
in thick sheets.
With the appropriate adaptation of the focal position, feed rate, la-
ser power and gas pressure, almost all aluminum alloys can be cut.
To optimize the cutting parameters, first the default parameters are
started and the specific parameters are adapted.
Adapt the cutting parameters based on the information given in section
5.3 ›Optimization of cutting parameters‹. Compare the cutting results
achieved with the figures in section 11 ›Cut evaluation‹.
Aluminum is a highly reflective material. If the laser beam is no longer

cutting the sheet, the laser power will be reflected. This can shorten the
life of the optics. It is recommended to monitor the production process
when cutting aluminum and its alloys.
The softer and purer an aluminum alloy is, the more difficult it is to cut
with laser. This can be recognized by the burrs on sheets under 3 mm
thick. In addition, the feed rate must be reduced by up to 40%, e.g. for
pure aluminum (Al 99.5%).

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6.7 Machining diverse materials
Material Comments
Titanium The cutting gases nitrogen or argon are employed for

cutting panels from titanium. The cutting parameter
database contains the parameters for titanium.
When cutting with nitrogen the cut edge oxidizes and
takes on a brown color. In addition, a burr forms on
the underside of the sheet (see Fig. 11.3-29).
When using argon, an oxide-free, clean cut edge
without burrs is produced (see Fig. 11.4-1).
Copper Both materials possess high reflectance and high

Brass thermal conductivity.
Brass can be cut with nitrogen up to a thickness of
6 mm, depending on the laser used (also Fig. 11.3-26
and Fig. 11.3-27).
Copper can be cut up to a sheet thickness of 3 mm;
oxygen must be used as the cutting gas.
Brass and copper in particular are very soft materials.
The underside therefore generally has burrs.
It is not economical to cut large amounts of copper on
a laser cutting machine. Water jet cutting is more
suitable.
Copper and brass may only be cut if a suitable device for ab-
sorbing reflections is installed on the laser cutting machine.
Reflections can otherwise damage the optical elements.

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Material Comments
Hardox, Weldox, These materials can generally be cut to good quality.

Domex The structural steel default parameters can be used.
Austenitic manga- Can be cut in sheets up to approx. 10 mm thick, but

nese steel causes a lot of smoke. It can also be cut with nitrogen
to reduce smoke development.
Tantalum, nickel-sil- These materials can be cut with Nitrogen. The rust
ver, Inconel and acid-resistant steel default parameters can be
used.
The maximum cuttable thickness is usually less than
the maximum cuttable thickness of rust and acid-re-
sistant steel.
Checker plate Can be easily cut. Checkers always down and adapt
the cutting parameters to maximum thickness.
Pure aluminum Is poorly suited to laser cutting because of the high

reflectance. The aluminum default parameters can be
used.
The maximum cuttable thickness is usually
2 ... 4 mm less than the maximum cuttable thickness
of AlMg3. The cutting speed must be reduced by up to
40%.
Plastics Plastics must not be cut on the laser cutting machine.

Observe safety instructions!
WARNING
Toxic vapors
The fumes given off on combustion are highly toxic.
They cannot be completely removed by the extraction
system.
Plastics must not be cut on the laser cutting machine.

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Material Comments
Wood, leather, card- Organic materials must not be cut on the laser cutting
board, paper machine.
The filters on the dust extraction unit are not suited to
this purpose and may be damaged. (see manufactur-
er's operating manual).
Observe safety instructions!
WARNING
Fire risk
Cutting organic material presents a fire hazard.
Organic materials must not be cut on the laser cutting
machine.
Material Comments
Silver Pure silver or silver-plated sheets may not be cut. The

reflectance is too great. This can damage the optical
elements.
Ceramics, tiles, Ceramics or brittle materials are not suitable for cut-
glass ting with laser. The heat input bursts the material.
Other materials Information on other materials can be obtained from

the manufacturer's customer service department.

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6.8 Plasma cut
Whenever a very bright, white-blue light is visible during cutting, it is

known as a plasma cut.
Fig. 6.8-1 Plasma cut in structural steel, 1 mm thick
Fig. 6.8-2 Plasma cut in stainless steel, 20 mm thick
The advantage of the plasma cut is the increased cutting speed of up to

50%.
The plasma cut is only possible at high laser power above 4 400 W.
The plasma cut is generated during laser cutting solely by editing the
cutting parameters. The cutting gas employed is nitrogen.
The plasma cut can be used on very thin sheets up to 2 mm thick and
on rust and acid-resistant steel of 15 ... 25 mm.
The roughness of the cut surface for a plasma cut is significantly great-
er than with a quality cut (see Fig. 3.3-3).
CutControl does not function for the plasma cut and is automatically de-
activated by the cutting parameters.
In laser cutting, the so-called plasma cut should not be confused with
the plasma cutting method.

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The following cutting parameters are different for the plasma cut, com-
pared to the normal cut.
Tab. 6.8-1 Cutting parameters for plasma cut compared to normal cut
Parameters Structural steel Rust and acid-resis-

0.8 ... 2 mma) thick tant steel
15 ... 25 mma) thick
Feed rate Much higher (30 ... 50%) Much higher (20 ... 40%)
Laser perfor- Higher (20 ... 40%) ⎯

mance
Nozzle clearance Higher (1.5 ... 2 mm in- ⎯

height for cutting stead of 0.7 mm)
Nozzle type H-nozzle instead of HK-noz- ⎯

zle
Nozzle diameter Greater (HK17/20 instead of ⎯

HK15)
Gas pressure Lower (20 ... 40%) ⎯

Focal position Same or slightly lower Much higher, to approx.
(0 ... 2 mm) 60% in main sheet
CutControl Deactivated Deactivated
a) Varies according to laser source in use
6.8.1 Practical applications
The operator decides whether to use the normal cut or the plasma cut.
The very high cutting speeds used in the plasma cut in sheets up to 2 mm
thick can only be properly utilized on Byspeed machines.
On Bystar machines, the cutting speed cannot be achieved on parts small-
er than 500 × 500 mm. The acceleration is too small. No parameters have
therefore been saved for plasma cutting in sheets less than 1.5 mm thick.

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6.8.2 Cutting parameters for custom sheets
The plasma cut can also be used with:

Rust and acid-resistant steel 0.8 mm thick with protective film
Electroplated steel plate, 0.75 mm thick,
etc.
The cutting parameters for these custom sheets must be determined by

the operator.
Cutting parameters for custom sheets can be most quickly determined if
the stored default parameters for the plasma cut are used as the basis.
Example:
For electroplated steel plate 0.75 mm thick, the cutting parameters for
structural steel 1 mm thick are used to start, (e.g. 10332r10.z5n). After-
wards, optimize the parameters: feed rate, laser power, gas pressure
and focal position, etc.
Fig. 6.8-3 Example of cut edges, cut with laser source 5 200 W
Plasma cut in rust and acid-resistant steel, 20 mm thick

Cutting gas nitrogen N2
Feed rate 0.45 m/min
Gas pressure 15 bar
Focal position approx.12 mm in sheet

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Fig. 6.8-4 Interface with quality cut
Quality cut in structural steel, 1 mm thick

Feed rate 11 m/min
Gas pressure 12 bar
Roughness of the cut edges approx. Ra3.2
Fig. 6.8-5 Interface with plasma cut
Plasma cut in structural steel, 1 mm thick

Feed rate 19 m/min
Gas pressure 10 bar
Roughness of cut edge approx. Ra12.5

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6.8.3 Plasma initial cut type in rust and acid-resistant steel, 15/
20 mm thick
In principal, the Bysoft Technology wizard selects the correct technology

for each laser type.
When plasma cutting it is important that the initial cut type is correctly se-
lected (especially for rust- and acid-resistant steel, 15 /20 mm).
The initial cut types differ according to sheet thickness and la-
ser power.
Tab. 6.8-2 Initial cut in rust- and acid-resistant steel, 15 / 20 mm thick, for laser source 5 200 W
Lead-in Comments
Example:
Thickness 15 mm
Laser source 5 200 W
Initial cut type Straight line at right angles

on the contour. This is selected automatically
by the technology wizard.
Example:
Thickness 20 mm
Laser source 5 200 W
The Technology wizard automatically selects the

initial cut type Straight line with arc on the
contour

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6.8.3.1 Partial plasma cut for sheet thicknesses up to 2 mm
It is possible to change between normal and plasma cut a number of times

within one part. This allows the part time to be minimized and the quality
to be partially improved.
Fig. 6.8-6 Partial plasma cut
It is possible to program into Bysoft how to cut which part sections. In

the example in Fig. 6.8-6, the two long straights (A) can be cut with the
plasma cut (CW).
All other sections, including the inner contour, are cut with the quality cut
(process macro 1). These optimizations are worthwhile for high part num-
bers in particular.

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6.8.4 Time comparison between quality and plasma cut
Steel disk, 1 mm thick, cutting gas Nitrogen N2 with laser source 5 200 W
Fig. 6.8-7 Structural steel disk, 1 mm thick
∅480 mm
∅100 mm
Cutting times:
Normal cut: Plasma cut:

Feed rate = 11 m/min Feed rate = 19 m/min
Cutting time = 26 s Cutting time = 15 s
Reduction in cutting time of more than 40% using the plasma cut
Use of the plasma cut in the thin sheet range up to 1.5 mm is

worthwhile primarily for large contours with few changes in di-
rection.

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Fig. 6.8-8 Comparison of cutting speeds for structural steel, cutting gas nitrogen N2
(machine type: Byspeed with laser source 5 200 W)
Cutting speed in [m/min]
Sheet thickness
A Plasma cut
B Normal cut
The diagram clearly shows that cutting is faster with the plasma cut and
up to 1.5 mm sheet thickness and production therefore more cost-effi-
cient.
The graphic also applies in principal for other materials, e.g. rust- and
acid-resistant steel with protective films or galvanized sheets.

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6.9 Engraving
6.9.1 General
Engraving is available as standard on every machine and can be used for

the following tasks:
labeling parts
engraving positions (crosses for drill holes)
engraving fold edges
applying visual elements and labels
pre-positioning of sheets or parts
Fig. 6.9-1 Engraving example
Engraving for angle measurements Engraving as inscription

Cutting gas oxygen O2 Cutting gas nitrogen N2
Engraving is chiefly used on rust and acid-resistant steel and structural

steel.
It is possible to engrave with nitrogen or oxygen. The same gas should be
used for engraving as for cutting to avoid the loss of time for purging.
The cutting parameters contain the engraving data. Engraving is easy to
program in Bysoft.

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Highly reflective materials such as copper, brass or shiny

surfaces are not suitable for engraving. The engraving can
be weak or may not appear at all.
With strongly-reflective surfaces, do not select an Engrav-
ing laser power higher than 2 000 W. The parameter En-
graving factor must not be greater than 5. Otherwise, the
reflected laser output can cause damage to the laser cut-
ting machine.
Engraved contours or lettering should not have a minimum
depth of less than 8 mm. This ensures good legibility.

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6.9.2 Assessing an engraving
The engraving depth is defined by the parameter values and the panel
surface. The stored parameters should be seen as guide values which can
be adapted as required (engraving depth). Optimum engravings can be
generated with this as the basis.
The saved parameters for engraving on structural steel (cutting

gas oxygen O2) are determined for the parts identification with
a minimum lettering height of 8 mm.
The Laser power, engraving determines the contrast of an engraving.

In structural steel, the depth of the engraving can be influenced.
Fig. 6.9-2 Fine engraving on structural steel with reduced laser power
Fig. 6.9-3 Deep engraving on structural steel with increased laser power
The Laser power, engraving must be adjusted to suit the surface finish
of the sheet and the desired visibility.

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6.10 Machining with process macros
Processing with process macros provides additional parameters to assist

optimum cutting of complex contours.
Programming is carried out in Bysoft. The cutting parameters must be al-
tered on the laser cutting machine. Five process macros are available (see
Tab. 6.10-1).
Fig. 6.10-1 Example with process macros
A Small contour (hole) with process macro 1

B Initial cut with process macro 2

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Tab. 6.10-1 Process macros available
Process macro Usage
1 Process macro 1 is automatically opened by the Bysoft

Technology wizard according to the rules for small con-
tours based on Tab. 4.2-3 and Tab. 4.2-4. The cutting
parameters are also determined for the small contours
(e.g. the small hole in Fig. 6.10-1).
2 For initial cut for moving into thick main sheets

For cutting on thin sheets with scanning (see Chapter
8.2.6 ›Thin sheet machining using scanning‹).
3 Available for customer-specific applications.
4 Available for customer-specific applications.
5 Vaporization of protective films on main sheets made of

rust and acid-resistant steel.

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6.10.1 Process macro 2 for the initial cut
Starting on the first geometry element of the initial cut (A) using the cut-
ting parameters in process macro 2 substantially improves process reli-
ability.
Fig. 6.10-2 Starting on the first geometry element
Starting with process macro 2 is mostly used on thick sheets:

The Bysoft Technology wizard automatically selects the process
macro 2 for the initial cut.

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6.10.2 Example with process macros
In the following example, the individual sections are cut using different
technologies (process macro 1, process macro 3 and CW).
Fig. 6.10-3 Structural steel, 6 mm thick, with different process macros
C A C
B A
A
C A C
A Bores ∅6.5 mm cut with process macro 1

B Gear teeth cut with process macro 3
C Banana holes Cut with CW
D Outer contour Cut with CW
The part is finished to a better quality in less time.

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6.11 Piercing method
Correct piercing is very important for the subsequent cutting process.

There are therefore various piercing methods.
Tab. 6.11-1 Process reliability and piercing time
Piercing method Process Piercing time

safety
Conventional, pulsed piercing Very high Very long

without monitoring
CPP Very high Short

Controlled Pulsed Piercing
Normal CW piercing High Short
Pre-piercing CW High Short
Pre-piercing CPP Very high Medium
The Bysoft Technology wizard selects the piercing method au-

tomatically. Manual adjustments can be made for special appli-
cations. See chapter 6.3.1.1 ›piercing‹

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6.11.1 Conventional, pulsed piercing (without monitoring)
This piercing method is only used with laser source 2 200 W and 3 000 W
(or when required).
Applications: Small bores

Piercing directly on the contour. Allows the inner
and outer parts to be used.
Advantage: small piercing hole
Disadvantage: Time-consuming piercing (with CPP, the piercing
time, pulsed mode is greatly reduced)
With conventional pulsed piercings, the sheet thickness in [mm]

corresponds approximately to the piercing time in seconds.
Using CPP (Controlled Pulsed Piercing), the piercing time for
sheet thicknesses up to 15 mm is substantially lower.

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6.11.2 CPP(Controlled Pulsed Piercing)
CPP (Controlled Pulsed Piercing) replaces the previous normal CW and

conventional pulsed piercing (without monitoring) with the laser source
4 400 W, 5 200 W or 6 000 W.
The parameter variants for pulsed piercing (CPP) are reduced and simpli-
fied, because the same values can be used across a range of sheet thick-
nesses.
CPP is used for the following materials and sheet thicknesses:
Material Sheet thickness
Structural steela) 1 ... 25 mm
Rust and acid-resistant steel 15 ... 25 mmb)
Aluminum 8 ... 15 mmb)
a) Great advantages above 4 mm sheet thicknesses

b) Max. sheet thickness varies according to laser source in use
CPP monitors the piercing process and starts to cut directly after success-
ful piercing. This produces short piercing times.
Fig. 6.11-1 Start hole for CPP piercing compared to normal piercing
CPP piercing Normal piercing
The start hole is considerably smaller.

Only a very small amount of material is ejected during the piercing cut.
Less heat input during the piercing cut
Lower wear on nozzles and lenses

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The parameters for CPP piercing are determined for mate-

rials as set out in Chapter 3.2 ›Material specification‹. The
CPP settings must be modified for different materials.
CutControl must be activated (check Setup machine and
Parameter values ).
All pierces executed using CPP must be programmed as
pulse pierces. If the laser source is correctly selected, the
Bysoft Technology wizard automatically selects pulsed
piercing (only with laser source 4 400 W, 5 200 W and
6 000 W).

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6.11.2.1 Sequence for a CPP piercing
CPP piercing is carried out in two steps. Step 1 prepares the penetration,
step 2 completes it.
First step
The starting point for CPP piercing is located approx. 8 mm above the
main sheet. The first step of CPP piercing begins from this position (with-
out delay).
Fig. 6.11-2 First step for CPP piercing
B
8 mm
A Lens
B Nozzle

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Second step
CutControl monitors the piercing cut to check when it has penetrated right
through the material. Once the main sheet is pierced, the laser cutting
machine immediately starts to cut.
Fig. 6.11-3 Second step for CPP piercing
A
D
C
B
0,6 ... 2 mm
A Lens
B Nozzle
C Mirror
D CutControl
If the piercing is too large and the material overheats, the values of the
following piercing parameters must be reduced:
Focal position
Pulse width, step 2
Piercing pressure, Gas type 1, step 2

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6.11.3 Normal CW piercing
This piercing method is the most common. Especially for fusion cutting us-
ing Nitrogen N2 in structural steel, rust-and acid-resistant steel and alumi-
num.
Advantage: rapid piercing

Disadvantage: Causes a relatively large start hole
6.11.4 Pre-piercing CW
Pre-piercing is used with laser sources 2 200 W and 3 000 W.
Application:
Parts with numerous bores and openings, or small parts tightly nested.
Procedure:
1. Cutting plan in Bywork with precutting functions. You can choose to

precut one part or the entire cutting plan in each case. Normally only
one part is precut.
2. Pre-piercing
3. Remove piercing splashes from panel (only after pre-piercing entire

cutting plan).
4. Leave sheet to cool if necessary.
5. Cutting

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Use a smaller nozzle for pre-piercing than for cutting. (e.g.

HK12 instead of HK17). The gas pressure during piercing must
be doubled in order to prevent splashes on the lens. The heat
input to the main sheet is reduced considerably by pre-piercing.
The piercing hole is smaller.
Once all holes are pre-cut, the axes automatically travel to the
origin. The nozzle can be easily replaced here.
The piercing gas pressurecan be reset to the original value
and the piercing time reduced to 0.
Using this procedure it is possible to cut holes and openings of
sizes 0.8 ... 1.0 × sheet thickness in normal thicknesses with-
out pulsing.
If the sheet heats strongly during cutting, it expands. This

can cause the pre-cut holes to be displaced.
Solution:
Reduce size of cutting area by dividing a large cutting plan (e.g. 1 × 2 m)
in two smaller ones (e.g. 1 × 1 m).
Because of the thermal expansion, single parts should only be cut in mul-
tiple cuts for no-tolerance parts.

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6.11.5 Pre-piercing CPP
CPP pre-piercing functions in the same way as CW pre-prepiercing (see

Chapter 6.11.4 ›Pre-piercing CW‹). In Bywork, you can choose to pre-
pierce one part or the entire cutting plan in each case.
With CPP pre-piercing, pulsed piercing is used (CPP)
Less heat is built up in the sheet during CPP pre-piercing. Also allow
the material around the piercing point can be allowed to cool before
cutting since all other piercings are made first.
The process of lowering into the existing piercing hole occurs with zero
laser output. The machine cuts immediately.
Applications:
Structural steel, 10 ... 25 mm thick with boring diameter, cutouts or
joint widths in sheet thickness range.
Small parts with many borings
Fig. 6.11-4 Example: Pre-piercing CPP

∅25 mm
65 mm
∅12 mm
65 mm
Pre-piercing CPP

Small bores: ∅ 12 mm
Technology, small bores: Process macro 1

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6.12 Microjoints
Microjoints or weld points prevent parts from tilting up or dropping down-

thus increasing process safety.
Tab. 6.12-1 Application overview
Microjoint Usage Benefits
Automatic micro- Structural steel The easiest and quickest

joints thickness 1 ... 10 mm way of preventing parts
Rust and acid-resistant from tipping over or falling
steel down
thickness 1 ... 10 mm The automatic microjoint is
Aluminum activated on the laser cut-
Thickness ... 10mm ting machine.
Several pro- Structural steel Increased safety, e.g. in low-

grammed micro- thickness 1 ... 10 mm staffed production combined
joints Rust and acid-resistant with automation
steel
thickness 1 ... 10 mm
Aluminum
Thickness 1 ... 10mm
Weld points Structural steel Simple breaking out of cut

thickness 4 ... 15 mm parts
Cutting of inner Highly dynamic cutting The inner parts do not need
parts all materials up to breaking out.
3 mm thick

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A cutout is cut to completion without microjoints. I.e. when the cut is

completed the laser beam joins the start of the cut gap again. However,
separation of the material occurs before the geometric end of the cut by at
least the width of the cutting gap (D).
Fig. 6.12-1 Part cut-out microjoint
A B C
A Laser beam at separation

B Lead-in
C Laser beam at start and end of cut
D cutting gap width
The cut out part begins to tilt just at this moment and the laser beam
meets it laterally and causes a burn. The laser beam is reflected in the
melt of this burn and thus causes a further burn in the cut-out.
If these burns are to be prevented, microjoints can be employed. The CNC
controls have an automatic microjoint function.

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Adding a microjoint causes the laser beam to switch off by distance (X)
before the geometric end of the cut-out. The cut-out thus remains con-
nected to the part and does not tilt.
The joint width (X) is selected at least as large as the cut gap (D).
Guide value for joint width X = approx. 0.8 mm
Fig. 6.12-2 Microjoint
E Work piece
F Cut-out

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6.12.1 Set microjoints
Microjoints can be applied in two ways:
Automatic
The machine does not cut the edges completely, a joint is created for
each initial cut (A). This function is activated on the laser cutting ma-
chine.
Programmed
In addition to the automatically defined microjoints, further microjoints
can be programmed with Bysoft (B).
To facilitate easy break-out of the parts, two microjoints on one axis are
expedient.
Fig. 6.12-3 Automatically set / programmed microjoints
A Automatically set microjoint

B Programmed microjoint
C Axis or breaking out of part
Automatic and programmed microjoints can be used in combi-

nation. These can be selected on the machine control unit.

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6.12.2 Microjoint welding
The weld joints must be programmed in Bysoft with microjoint welding.

Microjoint welding is especially beneficial for structural steels with sheet
thicknesses of 4 ... 15 mm. The weld points only fix the parts slightly
and are easier to breakout compared with joints.
The surface is also compromised by the weld point in the part.
The parameters for weld points are defined in the Setup values, ma-
chine (See instruction manual ByVision).
Fig. 6.12-4 Example of microjoint welding

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6.12.3 Alternatives to microjoints
Instead of microjoints, the inner parts can also be cut. This is especially
used for sheet thicknesses up to 3 mm. Bysoft provides simple aids. This
offers the advantage that manual breaking-out is not required.
Fig. 6.12-5 Cut inner part
A Inside
B Guide cuts for cutting the inner part
If microjoints are employed the initial cut type straight per-

pendicular must be used.
Further details on microjoints can be found in the Operating
instructions.

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6.13 Machining corners
6.13.1 Machining corners with corner tolerance
If a pointed corner is also required on the outer contour for further ma-
chining, it must be programmed without a rounding radius.
Tab. 6.13-1 Corner tolerance
Too large Correct
If the corner tolerance is too high, overshooting can occur on

the workpiece.

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6.13.2 Pointed corners in thick sheets (with Dwell time parameter)
In the thick sheet range, too much heat is input to the workpiece when
machining with loops. For this reason, the dwell time parameter should
be employed for machining pointed corners in the thick sheet range.
The axes travel to the corner and stop during the specified dwell time. Ma-
chining is then continued.
Fig. 6.13-1 Critical angle dwell time
Change of direction angle
If an entry is made for the dwell time parameter, the axes brake and
dwell at all change of direction angles which are greater than the defined
Critical angle dwell time parameter.
If the GO part angle is too small, a smaller radius is used auto-

matically. The dwell time is no longer active in this case.

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6.14 Support grids
6.14.1 Standard support grid
Fig. 6.14-1 Standard support grid
6.14.1.1 Advantages
Stable support grid, suitable for heavy main sheets

Manufacturable with CommenCut, resulting in optimum exploitation of
the sheet
Sheets on the grid can be moved by hand
6.14.1.2 Disadvantages
Spaces are quickly filled by slag
Rear of main sheet is soiled by splashes
The design of the support grid prevents small cut parts from falling.
These can remain erect and thus reduce process reliability

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6.14.2 Support grid for thin sheets
Fig. 6.14-2 Support grid for thin sheets
6.14.2.1 Advantages
Rear of main sheet is only slightly soiled

The large spaces fill only slowly with slag
The design of the support grid allows small cut parts to fall. This in-
creases process reliability
6.14.2.2 Disadvantages
The points of the support grid may be bent if the material is not proper-
ly loaded and unloaded
Sheets on the grid are not easy to move by hand

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6.14.3 Materials for support grids
Three different 3 mm thick materials are available for manufacturing the support grids.
Tab. 6.14-1 Comparison of materials:
Properties Material
Structural steel Stainless steel Copper
Properties of the various Suitable for all materials. With Suitable for all materials. Espe- Suitable for all materials. With
cutting grid materials limitations for stainless steel be- cially for machining stainless limitations for stainless steel and
during cutting cause the splashes from the steel steel. aluminum greater than 6 mm
grid can rust on the stainless thick, because the danger of a
steel surface. beam break is increased by the
copper grid for these materials
and sheet —thicknesses.
Manufacturing the cutting Laser machining possible Laser machining possible Laser machining not possible
grid
Price of the cutting grid Low Medium High
Life Low Medium High
Automation Parts can weld to the grid Parts can weld to the grid Parts do not adhere to the grid
Inner stability Medium High Low
Possible care / cleaning Not possible Not possible Possible

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Taking both the advantages and disadvantages of the geome-

tries and material properties into consideration, it can be seen
that there is no optimum grid for all applications.
The two tables of the shuttle table system can be equipped with
different support grids. This offers the advantage that the most
suitable can be selected respectively.

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6.15 Low-staff production
The most important criterion for low-staff production is process safety.

Procedure and working practice is therefore considerably different to nor-
mal production.
6.15.1 Recommendations
Only process cutting plans optimized for process safety in a manned

shift. In particular, erect or tilted parts must be prevented (see Chap-
ters 6.12 ›Microjoints‹ and 8.2.7 ›Erect parts after machining‹). Critical
part sizes range from 20 mm to approx. 150 mm.
Ensure that the long side of the parts lies perpendicular to the grid. In
many cases this can prevent tilting.
Cut only simple part geometries
Cut only simple sheet thicknesses (e.g. 3 mm)
Optimize cutting parameters. A reduction in the feed rate of approx.
10 ... 20% increases the process reliability significantly
Use CPP for piercing where possible
Monitor cutting with CutControl where possible
Use the nozzle cleaner
Use suitable main sheets (see Chapter 7 ›Materials‹)

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ST_Laser_Kap06.fm
Laser
Chapter 7
7 Materials
This chapter describes the factors specific to the material that influence
the cutting process.

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Materials Laser
7.1 Material properties
The cutting result on the workpiece can be a perfectly clean cut or a

ragged and burred cut edge.
The following are regarded as the principal influence factors on the cut
quality:
alloy constituents,
microstructure,
material surface
surface treatment
beam reflection,
thermal conductivity,
melting point.
7.1.1 alloy constituents,
Alloy constituents have a substantial influence on the strength, density,

weldability, and oxide and acid resistance of the materials. Significant al-
loy elements of steels are carbon, chromium, nickel, magnesium and zinc.
The higher the carbon content, the more difficult is the material to cut
(critical limit at about 0.8% carbon).
The following carbon steels can be cut well with the laser:
St 37-2, StW 22, DIN 1.203
The cutting quality and cutting performance are dependent on the alloy
components. In structural steel, a greater content of Si creates a rough
cut edge and increases slag formation and burring. Carbon content
>0.16% can lead to poor results on sharp edges and small holes.
We recommend you use laser sheets having controlled alloy constituents
when working at the extreme sheet-thickness range.
Tab. 7.1-1 C and Si content
Material C content Si content
RAEX 250 0,12% 0,01%
RAEX 420 0,13% 0,01%

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Laser Materials
7.1.2 microstructure,
Generally speaking, the finer the grain of the material structure, the bet-
ter the quality of the cut face.
7.1.3 Material surface
Material surface has a very significant influence on cutting results and cut
quality.
7.1.3.1 Positive effects
fine, even surfaces with microscale

sheet lightly oiled,
pickled sheets
hot-rolled oiled main sheets.
Sandblasted and shot-peened surfaces are only suitable to a limited ex-
tent but still better than rusty surfaces
Example:
Main sheets of the RAEX series, recommended by the machine manufac-
turer
7.1.3.2 Negative effects
loose rolling skin,

rust,
scale,
uneven surface with troughs and irregularities,
general soiling,
steel stamping, rolled in defects,
color markings.
Primer or color
Example:
Cheap St 52 sheet, exposed to weathering

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Materials Laser
7.1.3.3 Oil
Piercing splashes adhere less well to oiled surfaces. This means that ca-
pacitive sensing is disrupted less. Oiling can be carried out in a number of
ways:
Working with Crossjet
Purchase oiled main sheets
Oil dry main sheets manually.
WARNING
Fire risk
The oil on the sheet surface can be ignited by the laser
beam.
Flammable oils should not be used.
Always use welding protection oil
(MOTOREX PROWELD 264)

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Laser Materials
7.2 beam reflection,
The beam reflectance from workpiece surfaces is dependent on the base

material, surface roughness, focal position and surface treatment. High
beam reflectance occurs in alloyed aluminum, pure aluminum, silver, cop-
per, brass and rust and acid-resistant steel sheets. The higher the reflec-
tion, the more difficult it is to cut the material.
Fig. 7.2-1 Comparison of beam reflection by focal position
Large area
Higher beam reflection due to lower focal position. A focal position which
is too low can increase the output coupler temperature.
Small area
Low beam reflectance due to higher focal position (lower output coupler
temperature)

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Materials Laser
7.3 thermal conductivity,
Materials with low thermal conductivity require less power to melt the ma-
terial than materials with a higher thermal conductivity.
For example, the power required for stainless steel is below the values for
structural steel, despite the lower absorption at the process temperature.
On the other hand, copper, aluminum and brass, for instance, conduct a
substantial portion of the heat generated by the absorption of the laser
beam away. The heat is quickly conducted away from the point of the laser
beam, hindering the local melting of the material.

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Laser Materials
7.4 Heat-affected zone
During laser cutting, material alterations can occur at the edges of the cut
main sheet.
Tab. 7.4-1 Guide values for the extent of the heat-affected zone as a function of the base material and
the sheet thickness
Sheet thickness Heat-affected zone

in [mm] in [mm]
Structural Rust and acid- Aluminum

steel resistant steel
1 0,05 0,05 0,10
2 0,10 0,10 0,20
3 0,15 0,15 0,30
4 0,20 0,25 0,40
5 0,25 0,35 0,50
6 0,30 0,55 0,60
8 0,40 0,75 0,70
10 0,50 0,85 —
12 0,60 — —
In low-carbon and stainless steels the hardening of the heat-affected

zone is minor.
In high-carbon steels (e.g. Ck60) the boundary zones are hardened.
In hard-rolled aluminum alloys, the heat-affected zone is usually slight-
ly softer than the rest of the material.

ST_Laser_Kap07.fm
Materials Laser
7.5 Stresses
Cheap main sheets generally have substantially higher residual stresses

and warp accordingly during laser cutting. The stresses are created during
main sheet manufacture.
Qualitatively better main sheets posses lower residual stresses. Varying
levels of stress can often be observed within one sheet. The greatest
stress levels are at the edges (during manufacture) because of the quicker
cooling here. Additional production reliability can be achieved by careful
nesting.
Fig. 7.5-1 Stress behavior across the complete main sheet
Area 1: Low-voltage zone. Parts that warp heavily should be

nested in this area (e.g. long, thin strips).
Area 2: High-voltage zone. Large, non-complex parts should be
nested here.

ST_Laser_Kap07.fm
Laser
Chapter 8
8 High-dynamic cutting
This chapter provides information on the special properties of high-dy-

namic cutting with the Byspeed laser cutting machine.

ST_Laser_Kap08.fm
High-dynamic cutting Laser
In order to use this laser cutting machine to its optimum, the following
points must be observed for high-dynamic cutting in particular:
Part programming
Cutting parameters
Production
During ultra-dynamic cutting, the main sheet must be clamped.

This reduces the usable surface (see Chapter 1.2.2 ›Minimum
distance from sheet edge‹
8.1.1 Application
High-dynamic cutting is used primarily for sheet thicknesses in the

0.5 .... 1.5 range. Sheet thicknesses from 2 ... 3 mm are in a transition
zone.
From a sheet thickness of 4 mm upwards, the Byspeed machines operate
the same as the other laser cutting machines (with the exception of posi-
tioning). No special measures are required above this sheet thickness.
8.1.2 Part programming
The programming of the single parts can influence the machining process
considerably. Wrongly or below optimum programming of parts increase
machining time, can cause structural damage and increase wear on the la-
ser cutting machine.

ST_Laser_Kap08.fm
Laser High-dynamic cutting
8.2 Optimum parts programming
The part geometry is programmed using the Bysoft CAD/CAM application.

The machining technology is particularly important.
8.2.1 Initial cuts
Decide whether to work with or without initial cuts.
8.2.1.1 Machining without initial cuts
This is the fastest type of machining because piercing is directly on the

contour. The initial cut is dispensed with.
Disadvantage
The piercing point is visible even on the GO part. Machining without initial
cuts speeds up cutting of templates drastically, but is usually only suitable
for sheets thicknesses up to 1.5 mm due to the quality.
8.2.1.2 Machining with initial cut
A new cut type was developed for the Byspeed laser cutting machine —
so-called are initial cuts. These are supported by Bysoft Version 6.4 and
higher. The arc initial cuts allow a fine approach to the contour at high
speed and do not generate abrupt direction changes.
Fig. 8.2-1 Arc initial cuts with Byspeed
Arc initial cuts

ST_Laser_Kap08.fm
You can also use all other initial cuts supported by Bysoft. However, these
are not optimized for high-dynamic cutting.
In particular, the initial cut perpendicular to the contour is unsuitable be-
cause the cutting dynamics are impeded.
8.2.1.3 Initial cut type
In the following table the corresponding initial cuts are assigned to the ap-
propriate sheet thicknesses. However, different initial cut types can also
be used for differing quality requirements.
Tab. 8.2-1 Initial cut types and their applications
Initial cut type Usage
Without initial cut (piercing on the High-dynamic cutting of

contour) 0.5 ... 1.5 mm thick sheets
Straight line at right angles to contour Pulsed contours, general applications
Arc initial cut High-dynamic cutting of 0.5 ... 3 mm

thick sheets
Straight line with arc Sheet thickness 4 ... 20 mm, general

applications
Straight tangential Sheet thickness 10 ... 20 mm, outer

contours

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8.2.1.4 Initial cut point
You must generally ensure that the initial cuts reach the length defined in
Bysoft. If they are automatically shortened, the initial cut point must be
edited.
Tab. 8.2-2 Initial cut position
Optimum initial cut position Poor initial cut position

Length is not achieved
It is possible to use contours with and without an initial cut within one
part. For example, a template can be cut without initial cuts, all other ge-
ometries with initial cuts.

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8.2.2 Direction of rotation and cutting sequence in the part
The direction of rotation and the cutting sequence should follow a dynamic
sequence. Sharp changes of direction or reversals must be avoided.
Tab. 8.2-3 Direction of rotation and cutting sequence
Optimum direction of rotation Poor direction of rotation and

and sequence sequence
In templates with small and large contours, ensure that the

small contours are always cut first.
Do not position above a contour that has already been cut.
This avoids the risk of the cutting head possibly colliding with
a tilted part.

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Tab. 8.2-4 Cutting and positioning sequence
Optimum cutting and Poor cutting sequence

positioning sequence
8.2.3 Positioning in Bysoft
The head should always be raised for each positioning. Raising increases
process reliability and is just as fast as the lowered positioning function.
In Bysoft, the machining sequence must be specified as Po-

sitioning path optimized.

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8.2.4 Positioning the machine axes
In order to eliminate structural damage, the axes are not positioned in

straight lines, but use straights and arcs.
This means of positioning is applied by using the Floating cut start and
end parameter in the cutting parameters.
Input value: 0 = off

1 = on
2 = on + arc
Arcs should always be used for high-dynamic cutting. The cutting parame-
ters provided are accordingly defined for up to 3 mm sheet thickness.
8.2.5 Hole patterns
Hole templates are ideally cut in rows. The optimum initial cut is best done
in the quadrant.
If cutting is done without an initial cut an initial cut must be defined for a
change of row (if the row spacing is less than 8 mm) in order to avoid
structural damage.
Fig. 8.2-2 Optimum programmed hole template
If the centers (A) are less than 8 mm, the initial cut must be
applied at a change of row.

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8.2.6 Thin sheet machining using scanning
Scanning is the linear machining of rectangular and square holes. Linear

machining offers the advantage of requiring much fewer changes in direc-
tion. This enables a substantially shorter cutting time.
Compared to conventional machining this can be up to 50% faster for
scanning.
8.2.6.1 Schematic representation of the machining sequence
Machining with scanning is in two steps.
First step
First, all lines in an x-direction are processed (processing sequence
1 ... 4). Cut contour segments are highlighted.
Fig. 8.2-3 First machining step with scanning

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Second step
After the x-direction the y-direction is processed (processing sequence
5 ... 8). Cut contour segments are highlighted.
Fig. 8.2-4 Second machining step with scanning
8.2.6.2 Machining characteristics for scanning
Scanning can be used on all sheet types up to 2 mm thick.

Plasma cutting is a suitable method (see Chapter 6.8 ›Plasma cut‹).
Nitrogen (N2) is used as cutting gas for maximum cutting speed.
It often makes sense to use the process macro 2 cutting parameters
for the contours to be cut using scanning. This allows optimization of
the part.
Scanning is generally only worthwhile for large series', because of the
slightly greater programming effort. Bysoft supports programming of
scanning with a macro.
Scanning increases process reliability when cutting contours which do
not always fall safely through the support grid. These contours can be
additionally cut one or more times without losing a great amount of
time.
Microjoints can thus be avoided. The inner contours are all cut so small
that they fall safely through the support grid.
During scanning, piercing takes place directly on the contour. If this is
not permissible, scanning cannot be used.

ST_Laser_Kap08.fm
8.2.6.3 Machining example
Scanning is suitable primarily for repeating hole templates (e.g. for cov-
ers, cooling slots, mountings for filter pads).
Fig. 8.2-5 Cutting hole templates

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8.2.7 Erect parts after machining
It must be ensured at all costs that no parts remain erect, which could
causes a collision. This can be achieved by various means.
Tab. 8.2-5 Measures for preventing erect parts
Situation Action
Inner parts with diameters less than No measures necessary, parts always
approx. 15 mm fall through
Parts larger than 200 mm No measures necessary, parts always

remain flat
Microjoints Inner contours in danger of tilting and

the parts themselves between 15 mm
and 200 mm in x- and y-direction
must be safeguarded against tilting
Microjoints
and becoming erect by microjoints.

The best method is to program two
axis-symmetrical microjoints to facili-
tate easy break-out of the parts. The
microjoints are programmed in
Bysoft.
Cutting parts with the aid of guide By cutting the inner part into several
cuts pieces it is possible to ensure the
parts fall through safety without be-
Guide cut coming erect.
Advantage over microjoint:
The parts do not need breaking out.
Disadvantage:
Increased programming effort in
Bysoft. Guide cuts are supported in
Version 6.4 and higher.

ST_Laser_Kap08.fm
8.2.8 Thin sheet grids
To improve the safe falling through of parts even further, special thin sheet
grids can be employed. See Chapter 6.14 ›Support grids‹ for further infor-
mation.
8.2.9 Part machining sequence
For high-dynamic cutting the main sheet is automatically clamped at three

points on the left side. The cutting sequence should be selected so that
the sheet remains stable as long as possible, i.e. from right to left.
The numbers in the following cutting plan indicate the part cutting se-
quence.
Fig. 8.2-6 Part machining sequence
A B
13 12 4
3
21
20 19 14 11 10 5 2
15 6
1
22
16 7
18 9
17 8
A Clamping area of main sheet. See section 1.2.2 ›Minimum distance

from sheet edge‹
B Safety microjoints
C Machining the parts from right to left

ST_Laser_Kap08.fm
8.2.10 Warping
Parts such as perforated sheets and ventilation grilles have a tendency to

wart during cutting. In order to guarantee reliable production these parts
should not be located directly in the main sheet boundary zones, because
warping is strongest here. Parts (9) and (18) in Fig. 8.2-6 are correctly
positioned.
In order to stop warped parts from becoming erect, microjoints should
also be employed here.
Parts (5), (7), (14) and (16) in Fig. 8.2-6 are therefore safeguarded with
microjoints.
8.2.11 Pointed corners in thick sheets with loops
Loops are used when cutting thin sheets at high speeds. This procedure
offers the following advantages:
The axes travel around a pointed corner with a continuous direction
change
The part itself is cut at a uniform speed
Axis overshoot and additional burring are prevented
Heat input in the corner is reduced
Fig. 8.2-7 Corners with loops
A Loop
B Radius
C Part to be cut

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8.3 Cutting parameters
Special cutting parameters are available for high-dynamic cutting. These

are identified by plasma cut in the additional information for the file
name
Example:
A
A File name for cutting parameter

B Identifier for high-dynamic cutting (on-the-fly piercing)

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8.4 Production
In order to achieve maximum production reliability it is recommended to

individually test the parts to be cut with heavily reduced cutting and posi-
tioning speed and the check the simulation in Bysoft. These points should
be observed:
Never position over a previously cut contour
Observe the direction of rotation for cutting and positioning
No erect parts
Processing the cutting plan from right to left

ST_Laser_Kap08.fm
8.5 Quality of the main sheets
In the 0.5 ... 3 mm thickness range, special care should be taken that the
sheets are high quality and are transported with care.
The sheets should be as flat as possible and not display any warping. Dur-
ing storage, handling and transport sheets should be kept flat and not be
bent.

ST_Laser_Kap08.fm

ST_Laser_Kap08.fm
Laser
Chapter 9
9 Tube processing
This chapter provides information on tube processing using the Bystar la-
ser cutting machine.

ST_Laser_Kap09.fm
Tube processing Laser

ST_Laser_Kap09.fm
Laser Tube processing
Tubes can only be cut on the Bystar machine type. This has an optional ro-
tating axis.
Fig. 9.1-1 Example of a tube connection
Tubes are handled manually

During tube processing, the normal cutting parameters are adapted to
the tube in question (see Chapter 9.3 ›Adjustment of cutting parame-
ters‹).
Programming is carried out in Bysoft. This supports many different
versions of cut-outs, penetrations and sections.
If the tube part is to be subsequently welded, we recommend you cut
with Nitrogen (N2) Cutting with oxygen (O2) produces a flaky layer
which is not suitable for welding.
The maximum machined diameter is 315 mm
The maximum machined diameter is 15 mm

ST_Laser_Kap09.fm
The liquefied metal remains inside the tube and can be welded firmly to
the opposite side. Oiling the inner side of the tube with a non-flammable
welding protection spray prior to cutting can reduce the particles' firm
welding effect.
Fig. 9.1-2 Firmly welded material

ST_Laser_Kap09.fm
9.2 Reducing the heat
Unlike when welding main sheets, the laser beam and liquefied material
heats up the tube very strongly. The smaller the tube diameter to be ma-
chined, the stronger the heat.
When laser cutting an overheated tube, the result is a reduction in the
cutting quality.
The following measures reduce the heat in the tube:
Piercing
– Reduce Laser power, piercing or perform pulsed piercing (in struc-
tural steel)
– Reduce Piercing time
Cutting
– Reduce Laser power, piercing or perform pulsed piercing (espe-
cially in thin-walled steel tubes)
– Reduce Gas cutting pressure (especially when cutting steel tubes
with oxygen O2)
Selection of focal length

– Use 5" cutting head (instead of 7.5")

ST_Laser_Kap09.fm
9.3 Adjustment of cutting parameters
1. Measure largest wall thickness of tube. When welded, measure tubes

at weld seam.
2. Choose cutting gas (Nitrogen N2 or Oxygen O2)
3. Choose cutting parameter closest to measured wall thickness. If the

all thickness lies between two thickness values, use the highest
thickness.
4. Carry out heat reduction measures (see Chapter 9.2 ›Reducing the
heat‹).
5. In many cases the Laser power, cutting and the Laser power,
piercing may be reduced substantially.

ST_Laser_Kap09.fm
9.4 Machining square and rectangular tubes
It is more difficult to cut across the corner area than on the flat sides of
the tube. There is a particular strong risk of localized overheating.
Fig. 9.4-1 Cutting across corner area
When cutting with Oxygen (O2) it can be useful to cut the corner areas
using pulsed cutting. This reduces the heat input greatly and improves
parts quality. Programming is easy to carry out in Bysoft.
The parameter Y-feed rate, corner approach can be used to adjust
the cutting speed in the corner area.
Increasing the value of the parameter Nozzle clearance height for
cutting to 1 ... 1.2 mm can improve parts quality around the corners
to a certain extent.

ST_Laser_Kap09.fm
9.5 Quality of tubes and precision
The tubes contain enormous internal stresses from their manufacture

which may be released during laser cutting depending on the geometry.
This reduces the precision of the cut tube. Cheaper tubes on the market
often have greater stresses than more expensive ones.
Use tubes which are suitable for laser cutting. Your tube sup-
plier will advise you.
In cheaper tubes, the homogeneity of the alloying on the inside of the

tube is not always constant. This means the cutting quality is not al-
ways constant, especially when cutting steel tubes with Oxygen (O2).
Cutting with nitrogen N2 helps.
Parts precision can often be improved substantially by choosing the
right cutting sequence within the part.
Tubes have large shape and dimensional tolerances. This means that a
tube may arrive twisted or bent upon delivery. During laser cutting the
machine does not take these inaccuracies into account and a poorer
parts quality arises as a result.
Bent tubes can be straightened using appropriate heat treat-

ment.

ST_Laser_Kap09.fm
Laser
Chapter 10
10 Repositioning machines
This chapter provides information on the machining of oversized main

sheets using the Bystar L laser cutting machine.

ST_Laser_Kap10.fm
Repositioning machines Laser

ST_Laser_Kap10.fm
Laser Repositioning machines
Special attention must be paid when creating cutting plans for cutting
oversized main sheets (see Chapter 10.2 ›Creating the cutting plan‹).
Well thought-out cutting plans improve parts quality and precision and
make residual grid disposal easier.
Oversized main sheets do not normally have the usual sheet quality
compared with formats up to 3 000 × 1 500 mm. The surface is corrod-
ed or burned out in places, especially with sheet thicknesses above
8 mm. To improve cutting quality it may be useful to remove the cor-
roded surface by shot peening or sand blasting.
Main sheets have in places large internal stresses or inhomogeneous
crystal structures from their manufacture. This can reduce parts quality.
Your local steel trade can offer you advice on the various
sheet qualities.

ST_Laser_Kap10.fm
10.2 Creating the cutting plan
The cutting plans are created with Bysoft. The following points must be
observed:
Alternating machining is suitable for cutting plans containing long and
strip-shaped parts.
Strip-shaped parts are meant to be nestled in the middle of the main
sheet. This is usually where the least stresses are on the main sheet.
This ensures higher parts precision, and means the parts rise up less
during the cutting process.
Residual grid cuts in the X and Y direction are necessary to ensure a
safe cutting process. These prevent the parts and remaining sheet cuts
from rising up or becoming distorted during cutter and makes it easier
to remove the residual grid. It is worth displacing the parts or residual
grid cuts so that there are as few interruptions as possible. If a residual
grid cut cuts through the whole sheet, this also prevents the heat from
spreading (residual grid cut as heat separation). This may be helpful for
thicker sheets.
Nest the parts in such a way so that as few contours (inner and outer
contours) as possible lie on the separating position. This increases parts
precision.
Contours which are interrupted by a separating position require pulsed
piercing (when piercing directly on the contour) if the material used al-
lows for this. If this is not possible, normal piercing (CW) moving to-
wards the contour with an initial cut.

ST_Laser_Kap10.fm
Laser Repositioning machines
Fig. 10.2-1 Cutting plan for oversized main sheets
D
A
C
B B B
A Laser machine cutting area

B Remaining Grid Cuts
C Separating position
D Long and strip-shaped parts

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10.3 Production
You normally need to edit the following cutting parameters when cutting
corroded or poor quality main sheets:
Reduce Feed rate, cutting (in places up to 40%)
Reduce Laser cutting power
Nozzle diameter (use next largest diameter)
When cutting structural steel with Oxygen (O2), CPP piercing increases
production safety. See Chapter 6.3 ›Cutting structural steel‹

ST_Laser_Kap10.fm
Laser
Chapter 11
11 Cut evaluation
This chapter contains cut images which can be useful for evaluating and
improving cutting quality.

ST_Laser_Kap11.fm
Cut evaluation Laser

ST_Laser_Kap11.fm
Laser Cut evaluation
The following images are magnified up to 10x. This is why striations and
irregularities can even be seen on the optimum cut images.
The solutions described generally apply to all laser strengths
The solutions can also be extrapolated to other panel thicknesses

ST_Laser_Kap11.fm
11.2 Cutting with oxygen (O2)
11.2.1 Structural steel 37-2, 4 mm thick
Fig. 11.2-1 Optimum CW cut
Cut image:
Fig. 11.2-2 Nozzle diameter too large
Cut image:
Situation: Very coarse cut surface in approximately the upper

third of the cut.
Solution: use smaller nozzle (∅1.7 mm was used instead of
∅1.2 mm).
On the user interface, WORK view, the correct
nozzle for each material can be seen by pressing
the Info switch.

ST_Laser_Kap11.fm
Fig. 11.2-3 Laser power and gas pressure too low, nozzle diameter too small
Cut image:
Situation: Cut parts do not fall out of the panel independent-

ly. A bead of slag is found on the underside of the
panel. Good cut surface except the lower third.
Solution: Increase Laser power, cutting. Increase Gas
pressure, cutting. Use larger nozzle.
Fig. 11.2-4 Optimum pulsed cut face
Cut image:
Situation: rough, but regular cut surface (brown discoloration

in the lower third). Pulsed cutting was used.
Solution: the figure shows an optimum pulsed cut surface.
This is always rougher than the cut surface with
CW cutting.

ST_Laser_Kap11.fm
Fig. 11.2-5 Optimum cut
Cut image:
Fig. 11.2-6 Laser power and gas pressure too high
Cut image:
Situation: Rough, regular striations across the whole cut sur-

face.
Solution: Reduce Gas pressure cutting. Reduce Laser cut-
ting power.

ST_Laser_Kap11.fm
Fig. 11.2-7 Feed rate too great
Cut image:
Situation: Cut parts do not fall out of the panel independent-

ly. Very high drag across the cut surface, especially
the lower third.
A bead of slag is found on the underside of the
panel. Irregular cut surface.
Solution: reduce feed rate.
Fig. 11.2-8 Feed rate too low, laser power too high
Cut image:
Situation: Coarse, regular striations across the complete cut

surface.
Solution: Increase feed rate greatly. The example was cut at
half of the normal feed rate.
Reduce Laser cutting power.

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Fig. 11.2-9 Focal position too high
Cut image:
Situation: Coarse, regular striations on the upper face of the

panel.
Irregular cut surface.
A bead of slag may be found on the underside of
the panel.
Solution: Bring the focal position, cutting deeper (in the
figure it is 5 mm too high).
Fig. 11.2-10 Focal position too low
Cut image:
Situation: Coarse, irregular cut surface.

Solution: Bring the focal position, cutting higher (in the
figure it is 5 mm too low).

ST_Laser_Kap11.fm
11.2.3 Structural steel, 15 mm thick
Fig. 11.2-11 Reduce laser power and feed rate, nozzle diameter too small
Cut image: Surface
Cut surface with de- Cut surface with adapt-

fault parameters ed cutting parameters
Situation: Sand-blasted, heavily corroded surface.

The main sheet heats up strongly during cutting.
The top of the cut surface is very rough with heavy
striations. In part very heavy burns across the
whole cut surface.
Solution: Reduce Laser cutting power
– Default value: 4 000 W
– adjusted value: 3 300 W
Reduce feedrate
– Default value: 1 300 mm/min
– adjusted value: 1 100 mm/min
Use a larger nozzle
– NK 20 instead of NK 17

ST_Laser_Kap11.fm
11.2.4 Structural steel RAEX 420 Laser, 20 mm thick
Fig. 11.2-12 Optimum cut with NK nozzle
Cut image:
Fig. 11.2-13 Wrong nozzle shape used
Cut image:
Situation: Irregular, wavy cut surface in approximately the

upper third of the cut, with burns.
Solution: Use NK nozzle instead of HK nozzle.
the Info switch.

ST_Laser_Kap11.fm
Fig. 11.2-14 The heat concentration on the main sheet is too high
Cut image:
Situation: Cut parts do not fall out of the sheet independently

(are partially fused).
Very rough, irregular cut surface. Slag is not com-
pletely blown out.
Wide cut gap, particularly when starting and after
piercing.
Solution: The main sheet is much too hot. User laser sheet
such as RAEX.
Do not cut parts consecutively, but only every sec-
ond part.

ST_Laser_Kap11.fm
11.2.5 Rust and acid-resistant steel 1.4301, 6 mm thick
Fig. 11.2-15 Optimum cut with oxygen
Cut image:
Situation: Optimum cut with oxygen. The cut surface is much

coarser than with nitrogen.
The cut surface is oxidized. Easily removable beads
often form on the panel underside.
Cut image:
Situation: Cur surface is concave and has a coarse structure.

Heavy bead formation on the underside of the pan-
el.
Solution: Raise the focal position, cutting (in the figure it
is 3 mm too low).

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11.3 Cutting with nitrogen (N2)
11.3.1 Structural steel, hot galvanized, 2 mm thick
Cut image:
Situation: The cut surface is always considerably rougher

than without zinc. The cut changes with varying
zinc layer thickness. The thicker the zinc layer, the
rougher is the cut surface
There is always a very fine burr on the underside of
the panel. Electroplated sheets produce a much
finer cut image.
Fig. 11.3-2 Feedrate too great
Cut image:
Situation: Irregular, deep fissures in the cut face.Brown color-

ing downwards of the panel center.
Solution: Reduce Feedrate.
Fig. 11.3-3 Laser power too high
Cut image:
Situation: irregular, deep fissures in the cut face.

Solution: Reduce Laser cutting power.

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Fig. 11.3-4 Optimum, oxide-free cut
Cut image:
Cut image:
Situation: Hard, blue colored burr on the underside of the

panel. Heavy drag in the lower third of the cut sur-
face.

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Fig. 11.3-6 Focal position set too low
Cut image:
Situation: Rough, somewhat irregular cut from the panel cen-

ter down. Partial bead formation on the underside
of the panel.
Solution: Bring the Focal position, cutting higher (in the
Fig. 11.3-7 Gas pressure too low
Cut image:
Situation: Fine cut in the upper region of the cut surface.

However, the melted material is not completely
blown out.
Hard burr on the underside of the panel.
Solution: Increase the Gas pressure, cutting (in the figure
it is 5 bar too low).

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Fig. 11.3-8 Optimum, oxide-free cut
Cut image:

ST_Laser_Kap11.fm
Cut image:
Cut image:
Situation: Heavy (only removable mechanically) sharp burr

on the underside of the panel.
Good cut, may have rougher cut surface from pan-
el center.
Increase gas pressure. The increased gas pressure
ejects the molten material better.

ST_Laser_Kap11.fm
Cut image:
Situation: Bead formation on the underside of the panel.

Rough cut surface from center of panel. Danger of
laser beam break during cutting.
Solution: Bring the focal position, cutting higher (in the
figure it is 3 mm too low). Reduce feed rate, cut-
ting.
Fig. 11.3-12 Focal position too low, gas pressure too high
Cut image:
Situation: The laser beam no longer separates the main

sheet, the molten material is ejected upwards.
Bright blue light and loud noises from cutting pro-
cess.
Solution: Raise focal position, cutting. Reduce gas pres-
sure.

ST_Laser_Kap11.fm
Fig. 11.3-13 Gas pressure too low
Cut image:
Situation: Heavy burr on the underside of the panel. Washed

out, irregular cut surface with heavy drag from ap-
prox. center of panel thickness.
Solution: Increase gas pressure (in the figure it is 4 bar too
low).
Fig. 11.3-14 Feed rate too low
Cut image:
Situation: Clean cut surface in the upper two thirds of the cut
surface.
Heavy drag in the lower third of the cut surface.
Heavy (only removable mechanically) sharp burr
on the underside of the panel.
Solution: Increase the Feedrate, cutting (in the figure it is
only half of the default value). Increase Cutting
gas pressure.

ST_Laser_Kap11.fm
Fig. 11.3-15 Feedrate too great
Cut image:
Situation: Good quality in the upper half of the cut surface.

Increasing roughness and increasing drag in lower
half of the cur surface.
Solution: Reduce the Feed rate, cutting (in the figure it is
20% greater than the default value).
Fig. 11.3-16 Beam diameter too large
Cut image:
Situation: Good quality in the upper half of the cut surface.

Increasing roughness and increasing drag in lower
half of the cur surface.
Bead formation on the underside of the panel.
Solution: Reduce the beam diameter, cutting (in the figure it
is 1.5 mm more than the default value).

ST_Laser_Kap11.fm
Fig. 11.3-17 Optimum plasma cut
Cut image:
Situation: Optimum plasma cut. Coarse, regular cut surface

with wavy drag.
Removable bead formation on the underside of the
panel.
Solution: If the quality is insufficient, a different cutting
method must be considered (e.g. water jet cut-
ting).

ST_Laser_Kap11.fm
11.3.6 Aluminum AlMg3, 3 mm thick
Cut image:
Situation: optimum cut.
Fig. 11.3-19 Gas pressure too high
Cut image:
Situation: strong irregularities in cut. Blue flashes in cutting

gap when cutting.
Solution: Reduce Cutting gas pressure (in the figure it is
3 bar too high).
Fig. 11.3-20 Laser power too high
Cut image:
Situation: strong irregularities in cut. Blue flashes in cutting

gap when cutting.
Solution: Reduce Laser cutting power.

ST_Laser_Kap11.fm
Cut image:
Situation: fine cut face in the upper two thirds of the cut.
Heavy drag in the lower third of the cut face. Hard,
difficult to remove burr on the underside of the
panel.
Solution: Set the Focusing position, cutting lower (in the
Fig. 11.3-22 Focal position set too low
Cut image:
Situation: Clean cut face. Bead formation on the underside of

the panel.
Solution: Set the Focusing position, cutting higher (in the

ST_Laser_Kap11.fm
Fig. 11.3-23 Optimum cut with NK nozzle
Cut image:
Situation: Optimum cut with NK nozzle. Uniform cut surface,

somewhat rougher with increasing panel thickness.
Easily removable burr on the underside of panel
Fig. 11.3-24 Wrong nozzle shape used
Cut image:
Situation: Uniform cut surface, somewhat rougher with in-

creasing panel thickness. Coarse tears across the
complete cut surface. Easily removable burr on the
underside of panel.
Solution: Use NK nozzle instead of HK nozzle.
the Info switch.

ST_Laser_Kap11.fm
Fig. 11.3-25 Focal position too high, gas pressure too low
Cut image:

creasing panel thickness. Hard, long burr.
Solution: Set the Focusing position, cutting lower (in the
figure it is 3 mm too high). Increase Cutting gas
pressure.

ST_Laser_Kap11.fm
11.3.8 Brass, 5 mm thick
Cut image:
Situation: optimum cut. Uniform cut surface, somewhat

rougher with increasing panel thickness. Bead for-
mation on the underside of the panel.
Cut image:

creasing panel thickness. Brown-black coloring
from main sheet center down.
Solution: Set the Focusing position, cutting higher (in the
figure it is 2.5 mm too low).

ST_Laser_Kap11.fm
11.3.9 Copper, 3 mm thick
Cut image:
Situation: optimum cut. Rougher cut surface with increasing

panel thickness. Because copper is very soft a
heavy burr forms on the underside of the panel.
11.3.10 Titanium, 3 mm thick
Cut image:
Situation: Optimum cut with nitrogen. Titan oxidizes when

cut with nitrogen. This causes a brown to black col-
oring across the complete cut surface. Hard, re-
movable burr.

ST_Laser_Kap11.fm
11.4 Cutting with argon (Ar)
11.4.1 Titanium, 3 mm thick
Cut image:
Situation: optimum cut. Fine, oxide-free cut edge. Because ti-

tanium is an expensive material, the oxide-free
quality is generally demanded.

ST_Laser_Kap11.fm
11.5 Piercing with oxygen (O2)
Fig. 11.5-1 Standard piercing in structural steel from 4 mm thick.
CPP piercing:
Comments: Standard piercing in structural steel from 4 mm

thick. The piercing hole is only slightly larger than
the cutting gap. Only a small amount of material is
heated and ejected. Both criteria increase process
reliability.
Very well suited to small bores.
Fig. 11.5-2 Uncontrolled piercing at high power
CW piercing:
Comments: Uncontrolled piercing at high power creates a large

piercing hole.

ST_Laser_Kap11.fm
11.6 Piercing with nitrogen (N2)
Fig. 11.6-1 Piercing on dry main sheets
CW piercing:
Comments: The melt ejected upwards during piercing is eject-

ed on to the surface in a star shape. This can ad-
here very strongly.
Small bores can interfere with capacitive sensing.
This reduces the quality.

ST_Laser_Kap11.fm
Fig. 11.6-2 Piercing on oiled main sheets
CW piercing:
Comments: Practically no splash on the main sheet. The up-

wardly ejected melt cannot adhere due to the oil
film and runs off.
High process reliability and quality even for small
bores. The oil film can be applied either using
Crossjet or manually.

ST_Laser_Kap11.fm
Fig. 11.6-3 Small piercing
CW piercing:
Comments: Small piercing. The melt can fill the piercing after
starting. This can cause the laser beam to break.
Highly suitable for piercing directly on the contour.
Fig. 11.6-4 Large piercing
CW circular pierc-
ing:
Comments: Large piercing. High process reliability for panel

thicknesses above 6 mm.
The melt cannot fill the piercing after starting.

ST_Laser_Kap11.fm
Fig. 11.6-5 Large piercing
CW circular pierc-
ing:
Comments: Large piercing using circular piercing. Excessive

ejected melt can influence the capacitive sensing
when cutting small holes.
Heavy soiling of the nozzle when piercing. This re-
quires regular nozzle cleaning.
Fig. 11.6-6 Minimum piercing size
CPP piercing:
Comments: Minimum piercing size. Only little ejected melt.

Small bores can be cut with high process reliability.
Minimum soiling of nozzle, therefore regular nozzle
cleaning unnecessary. Long nozzle service life.

ST_Laser_Kap11.fm
11.7 Quality of cut edges
Using oxygen O2 as the process gas produces an oxidized surface. This

surface is not suitable for subsequent surface treatment (e.g. varnishing,
staining, galvanizing etc.). The layer of oxide must be removed before
subsequent surface treatment.
Using nitrogen N2 as the process gas produces an oxide-free surface.
Quality of the cut edge, see Chapter 1.3.2 ›Quality of the cut edge‹

ST_Laser_Kap11.fm
Laser
Chapter 12
12 Fault finding
This chapter provides support in finding the causes of deteriorations in cut

quality.

ST_Laser_Kap12.fm
Fault finding Laser

ST_Laser_Kap12.fm
Laser Fault finding
Optimum machining quality can only be achieved under the following con-
ditions:
Precise adjustment of the laser cutting machine
Maintenance as per maintenance schedule
Working materials in accordance with requirements,
Workpiece surface is rust and cinder-free (etched, pickled or polished)
Suitable parameters for the material and panel thickness at hand
Parameters harmonized to each other
The following points must be examined if the machining quality falls com-
pared to previous results:
1. Parameters
2. Cutting head
3. Beam guidance system
4. Laser module

ST_Laser_Kap12.fm
Fault finding Laser
12.2 Parameters
Never overwrite the default parameters delivered with the laser cutting
machine.
A new folder must be created for the customized cutting parameters.
If cut quality deteriorates, examine whether the default parameters have
been changed substantially compared to your customized parameters.

ST_Laser_Kap12.fm
Laser Fault finding
12.3 Cutting head
Focal length in accordance with parameters

Nozzle shape according to parameters,
Lens clean
Nozzle centered accurately
Focal position
Lens correctly mounted and fixed.
Check water cooling on cutting head

ST_Laser_Kap12.fm
Fault finding Laser
12.4 Beam guidance system
Deflecting mirror (cleanliness, fit, cooling)

Cutting head positions 1 ... 4 for adjusting the optics
Laser mode in Plexiglas cube
Positive pressure in the beam channel and bellows
Solvents in the ambient air
Sufficient air quality for the beam channel ventilation

ST_Laser_Kap12.fm
Laser Fault finding
12.5 Laser module
Optical impression of gas discharge

Power check
Tube current
Positive pressure in output coupler
Polarizing mirror
Beam divergence system
Density of laser
Output coupler (service)
Total reflector (service)
Deflecting mirror (service)

ST_Laser_Kap12.fm
Fault finding Laser

ST_Laser_Kap12.fm

Laser Cutting Technology

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Laser

Issued on: 01.2007

Cutting technology © Bystronic Laser AG, 2007 0-1

0-2 © Bystronic Laser AG, 2007 Cutting technology

Cutting technology: ST_Laser_V20_en.fm

Purpose of this document

Cutting technology © Bystronic Laser AG, 2007 0-3

0-4 © Bystronic Laser AG, 2007 Cutting technology

Czech Republic England

Cutting technology © Bystronic Laser AG, 2007 0-5

Netherlands North America

Russia / Ukraine and Rest CIS Singapore

Slowakei South Africa

South Korea Spain / Portugal

0-6 © Bystronic Laser AG, 2007 Cutting technology

Rest of the World

Cutting technology © Bystronic Laser AG, 2007 0-7

0-8 © Bystronic Laser AG, 2007 Cutting technology

1 Definitions and ranges

1.1 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Cutting technology © Bystronic Laser AG, 2007 0-9

2 The laser cutting process

2.1 Laser cutting areas . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

0 - 10 © Bystronic Laser AG, 2007 Cutting technology

3 Design and manufacture

3.1 Factors influencing the manufacturing process . . . 3–3

Cutting technology © Bystronic Laser AG, 2007 0 - 11

4.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 4–3

0 - 12 © Bystronic Laser AG, 2007 Cutting technology

5.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 5–3

Cutting technology © Bystronic Laser AG, 2007 0 - 13

6.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 6–3

0 - 14 © Bystronic Laser AG, 2007 Cutting technology

Cutting technology © Bystronic Laser AG, 2007 0 - 15

7.1 Material properties . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

0 - 16 © Bystronic Laser AG, 2007 Cutting technology

8.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 8–2

Cutting technology © Bystronic Laser AG, 2007 0 - 17

9.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 9–3

0 - 18 © Bystronic Laser AG, 2007 Cutting technology

10.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 10 – 3

Cutting technology © Bystronic Laser AG, 2007 0 - 19

11.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 11 – 3

0 - 20 © Bystronic Laser AG, 2007 Cutting technology

12.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . 12 – 3

Cutting technology © Bystronic Laser AG, 2007 0 - 21

0 - 22 © Bystronic Laser AG, 2007 Cutting technology

1 Definitions and ranges

This chapter provides important information needed to ensure a safe cut-

Cutting technology © Bystronic Laser AG, 2007 1-1

1-2 © Bystronic Laser AG, 2007 Cutting technology

1.1.1 Part area

Fig. 1.1-1 Calculating a part area

Element Dimension Area

1 Square 100 x 100 mm 10 000 mm2

2 bore ∅20 mm -314 mm2

3 Rectangular 110 x 20 mm -314 mm2

4 bore ∅20 mm -2 200 mm2

A Part area 7 172 mm2

Cutting technology © Bystronic Laser AG, 2007 1-3

Fig. 1.1-2 Examples of part areas

1-4 © Bystronic Laser AG, 2007 Cutting technology

1.1.2 Parts size

Tab. 1.1-1 Defining the parts size as a function of sheet thickness