Laser Cutting

University of Texas at Austin

ME392Q – Manufacturing Processes: Unit Process

By
Riko Tantra

Date: April 22, 2003

 Presentation Overview
Laser & Laser Cutting Fundamentals
Material Removal Types
Equipment
Different Type of Lasers for Laser Cutting
Laser Parameters for different materials
Cutting Speed & Depth of Cut
Comparison of Laser cutting to other method
Costs
Advantages & Disadvantage of Laser Cutting
References
 Laser Fundamentals
Acronym of Light Amplification
Stimulated Emission of
Radiation

Basic:
1. Atoms initially at the Ground
State
2. The atoms go to Excited
State when a high energy is
applied (called ‘pumping’)
3. When atoms moves back to
the ground state, photons
(particle of light) are released

Laser Beam Characteristics:

a. Monochromaticity
b. Coherence
c. Very Limited Diffraction
d. Extremely high Radiance
Laser Beam Formation Example (Ruby Laser)
1. Laser in OFF state
4. Photons runs parallel to the
rod direction & reflect back
and forth and stimulate
emission on more atoms

2. Flash Tube excite atoms in

the Ruby Rod

5. Laser light passes through

partially-reflective mirror

3. Some Atoms emit Photons

 Laser Machining

Laser Cutting
 Material Removal Types of Laser Cutting
1. Vaporization: low vaporization
temperature materials
2. Fusion: Material is melted &
ejected (by an inert gas jet)
3. Reactive Fusion: dross is no
longer a metal, but an oxide
4. Thermal stress cracking or
controlled fracturing: for brittle
materials
5. Scribing: Mechanical snapping
along scribed line
6. Ablation (Excimer laser):
breaking organic material
bonds
7. Burning in reactive gas
 Equipment
1. Laser-beam generator
2. Beam delivery: Circular polarizers,
mirrors, beam splitters, focusing
lenses and fiber optic couplings
3. Workpiece positioning
4. Auxiliary devices: Laser head,
safety equipment, etc.
In addition, assist gases also required
Smart Laser Cutting System

Picture from
[2]
 Different Type of Laser for Laser Cutting
1. CO2 laser (most
commonly used for
laser cutting):
a. Have the highest
Continuous Wave
(CW) power
b. Capable to extract
as much as 10kW/m
of discharge tube (with CO2 Laser Schematic [8]
traverse flow laser)
c. Have a high energy
efficiency (up to 10%)
d. Capable of both
CW and Pulsed
operation (5kHz)
2. Nd:YAG:
a. has the highest peak power for pulsed
operation
b. May be operated in either CW or pulsed
(200Hz) temporal modes

3. Nd: Glass: more economical but has lower

thermal conductivity. Used for low pulse
repetition rates (1Hz; due to its poor thermal
properties) & high pulse energies. Ideal for
drilling.

4. Nd: Ruby: low energy efficiency & power,

Limited to pulsed laser operation
5. Excimer:
a. High power (Average power over 100W) pulsed beams
(1kHz)

b. Laser length limited to 2-3 m due to the absorption

coefficient  Material narrower materials that can be
processed vs. that of CO2 laser

c. Used to machine solid polymer pieces, remove

polymer films, micromachine ceramics, medical
applications

d. Ablation material removal process

e. Higher precision & less heat affected zone vs. CO 2 &

Nd:YAG lasers

f. Produces large area beams  use mask to produce

series of holes. 5000 holes in a polymide sheet in 3 sec
vs 50 sec using CO2 or Nd:YAG lasers.
 Laser Beam Temporal Modes
Continuous Wave (CW) commonly
results in the highest cutting
speed & better surface finish.
Roughness is determined by
thickness, alloy content, etc. [52]

Pulsed beam results in the fewest

thermal effects & least distortion
of workpiece. With drilling
overlapping holes (see right), it’s
possible to cut with smoother
surface.
Comparison of Major
Material Machining Lasers
Cutting Considerations for Different Materials
A. Ferrous Metals:
i. High efficiency due to easy-to-remove oxide
creation
ii. One approximate rule:1.5kW laser power will
cut
a. 1mm thick mild steel at approx 10m/min
b. 10mm thick mild steel at approx 1m/min
B. Non-Ferrous Metals:
i. Mostly less efficient than cutting steel, due to
the higher reflectivity, thermal conductivity &
less efficient oxidation reaction
ii. Similar edge qualities to SS
C. Non-Metal: Most non-metallic materials are
highly absorptive at CO2 laser wavelength.
Cutting process:
i. Melt Shearing (mostly for thermoplastic): cut
very quickly & high quality edges
ii. Vaporization: usually only for acrylic
iii. Chemical degradation: slow cutting, high
temperature, but flat & smooth result
Cutting Speed on Mild Cutting Speed on
Steel Stainless Steel
Cutting Speed on Aluminum Cutting Speed on Acrylic

Max Cutting Speed for Polymer: V=PQt-B

P = Laser Power (W) t = material thickness (mm)
Q = an experimentally derived constant for the polymer
B = an experimentally derived constant for the material
 Power setting for different cutting
applications [9]
Application Recommended Cutting
Requirement Laser Power consideration

Thin materials: 150 Watt Average, Up to 0.04” thick can

Non- metals 450 Watt peak be cut at full speed of
1200in/min with 150
watt
Thicker materials: 250 watt to 500 watt Up to 1”: Power 
Non-metals average - up to 1500 Cutting Speed  ,
watt peak cleaner result & lower
HAZ
Metals 150 watt to 500 watt Al, Brass, SS use 500
average - up to 1500 W due to its
watt peak reflectivity. As
thickness , also
power need to be 
 Laser Cutting Analysis
Cutting depth, s
s = 2.a.P/(1/2..v.d.(cp.(Ts-To)+L))

a = absorbtivity of the material

P = Beam power
 = density
v = scanning velocity
d = spot diameter (=2.R)
cp = specific heat
Ts = surface temperature
To = ambient temperature
L = latent heat of fusion
Typical CO2 Laser Cutting Parameters
Characteristics of cuts by Laser Cutting
1. Kerf Width: CO2 laser range from 0.1-1mm

2. Roughness: 0.8mm material  1 m

10 mm material  10 m

3. Dross: undesirable; removed by extremely

high assist gas or by applying antisplatter
coatings (i.e. graphite)

4. Dimensional Accuracy: main problem is

thermal effect (distortion)
Comparison of Laser cutting to other methods
 Cutting Cost example
CAPITAL COST:
a. Laser Generation: $ several hundred thousand
b. Cooling system, power supply, multi-axis robot: exceed cost of
laser
OPERATING COST:
i. CO2 lasers cost $70-$100/watt (Nd:YAG costs 10-20%more)
ii. Safety devices
iii. Skilled operator

Example CO2 system operating at 1500W

a. Electricity at 7cent/kW-hr $2.10/hr
b. Internal laser optics $2.06/hr
(lifetimes per manufacturer)
c. Focusing lens (500hr lifetime) $1.10/hr
d. Laser gas $1.03/hr
e. Assist gas $3.60/hr
(based on 10ga. Carbon steel w/ O2 assist)
TOTAL: $9.89/hr
 Advantages of Laser Cutting
1. Laser machining is a thermal process:
depends on thermal and optical rather than the
mechanical properties

2. Laser machining is a non-contact process: No

cutting forces generated

3. Laser machining is a flexible process

4. Laser machining produces a higher precision

and smaller kerf widths results (as small as
0.005mm dia hole)
(cont’d…)
 Advantages of Laser Cutting (Cont’d)
5. For most industrial materials up to 10mm thick,
laser cutting has a significantly higher MRR

6. Laser Cutting has ability to cut from curved

workpieces

7. For cutting fibrous material (wood, paper, etc.)

laser cutting eliminates residue and debris
 Disadvantage of Laser Cutting

1. Low energy efficiency

2. Material damage: Heat affected zone (HAZ)

3. Laser cutting effectiveness reduces as the

workpiece thickness increases

4. Laser cutting produces a tapered kerf shape

(due to divergence)
 References
1. Chryssolouris, G., Laser Machining Theory and Practice,
Springer-Verlag, New York City,NY 1991
2. Steen, W M., Laser Material Processing 2nd ed., Springer-Verlag,
London 1998
3. Migliore, L., Laser Materials Processing, Marcel Dekker, Inc, New
York City, NY 1996
4. How Laser Works. Maschler, M. Howstuffworks homepage April
18. 2003. <http://science.howstuffworks.com/laser.htm>
5. Wang F.F.Y, Laser Materials Processing, North-Holland, New
York City, NY 1983
6. Benedict, G.F., Nontraditional Manufacturing Processes, Marcel
Dekker, New York City, NY 1987
7. Kalpakjian, S., Manufacturing Processes for Engineering
Materials, Addison Wesley Longman, Menlo Park, CA 1997
8. Fast Axial Flow Lasers – Theory of Operation. April 18. 2003.
PRC Laser Homepage March 14, 2000
<http://www.prclaser.com/laser101.htm>
9. Advance Laser Cutting Technology. April 18. 2003. Beam
Dynamics Homepage
<http://www.beamdynamics.com/Products/faqs2.html>