YAG laser machines vertical cavity walls

Lasertec Nd:YAG laser machining technology has made it possible to machine vertical walls in mould and die pockets and cavities using six axes CNC.

Since the Lasertec laser machining became commercially exploitable last year for working durable materials, sales figures have surged, reports Deckel Maho.

This is true for both the DML 40 laser machine and the DMU 60 L combination machine.

This is due to the laser beam's advantage over other machining technologies: even very fine cavities in very different materials right down to ceramics can be worked on.

In addition, laser is a wear-free tool and thus ensures very high process reliability.

Last but not least, the Lasersoft 3D programming software makes it possible to produce finished workpieces from the 3D geometrical data directly, that is to say without any additional machining steps.

Despite all this, during the past months there were several enquiries which the Lasertec offers were not able to satisfy.

In concrete terms, these enquiries concerned those areas of mould and model making which not only wanted to create fine cavities with laser but also needed definable inclinations near the vertical for removing items from the mould.

As from the IMTS fair in Chicago, these users can be helped.

The solution is as simple as it is fast to explain.

In addition to three optical axes, the new DML 40 SI has three mechanical axes.

Furthermore, a sensor continuously measures the amount of material removed during the process, with the result that it is not only possible to achieve the above-mentioned mould-release inclinations with, for example, 1 or 2 degrees, but also to create vertical walls.

And if that were not enough, it was possible, by means of additional optimisations, to improve the achievable surface quality to up to1.0 microns Ra .

By the way, the far-reaching possibilities of six-axis laser machining were not achieved through complicated programming.

As with the conventional DML 40 or with the DMU 60 L, the entire lasering process and the movements of the machine continue to be generated automatically by Lasersoft 3D software.

Geometrical data are taken over by CAD systems in the STL format.

For programming, only the geometry of the material to be cut is needed; in the programming system, these data are subsequently broken down in layers which are then used as a basis to generate laser ghost lines.

The calculation is done automatically, and even operating the actual control computer does not require any special CNC skills.

All of the above features are combined in a unique laser machine marking the final breakthrough of lasering for industrial use.

Whether it is used as a stand-alone application or integrally combined with conventional milling, NC-controlled lasering is predestined for moulds with contours with very fine geometrical features.

It is predestined for this because production of the respective workpieces is faster and more cost-effective than with conventional procedures.

In addition, the broad range of materials that can be processed not only includes steels and non-ferrous, light and precious metals but also ceramic materials which could not be milled or eroded up to now.

Technical data: DML 40 SI has X-, Y-, Z axis of 400/300/5 50mm The Laser work area is 70 x 70mm.

Table size is 300 x 400mm Max.

table load is 50kg.

Surface roughness machined is 1.0 micron.

Metal removal rate (steel) is 5mm3/min approx.

Diameter of laserbeam is 0,1mm Laser type is a Q-Switch YAG laser with an output of 100W.

The DMU 60 L has X-, Y-, Z axis of 600/525/500mm.

Main drive is 15kW and spindle speed range is up to 12000 rev/min.

Feed range isd up to 10.000mm/min and rapid traverse, in X/Y/Z, is 18/18/15m /min.

Control is the MillPlus or Heidenhain TNC 430.

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