Introduction
Laser cutting is an excellent technology of cutting thin metal and other materials using laser beams to melt or vaporize them or to follow the cutting path. Laser cutting involves using a high power laser to produce a powerful beam that is directed towards the material being cut so as to cut along the required path without affecting the other parts of the material.
Laser cutting systems depend extensively on the performance of compressors because they offer a clean and dry air pressure that is essential in several operations of the laser cutting system. The main applications of compressors in laser cutting include:
Assist Gas Supply
While in laser cutting, one of the most critical applications of the compressor is in supplying the assist gas. Helium, which is an assist gas together with oxygen, nitrogen, and air are blown at a high pressure across the laser cutting region. The assist gas aids in the clearance of the molten material from the cut and clears vapors and debris to ensure a neat cutting edge.
Cylinder compressors or nitrogen generator for laser cutting are used to provide assist gasses at the appropriate pressure for laser cutting. The capacity and pressure rating of the compressors are determined by the Laser Cutting System assist gas consumption. It is usual to employ rotary screw and piston Compressor in order to supply oil free air/ nitrogen for assisting gas in laser cutting pressures ranging from 10 bar to 20 bar.
Inert Gas
These assist gasses are delivered towards the cutting zone to enhance the quality and efficacy of laser cutting. They assist in their removal from the kerf when cutting is undergoing during production of the workpiece. Laser cutting uses assist gas in cutting materials such as the mild steel to a cheaper compress air or nitrogen. Purged or filtered and pressurized by either a compressor to deliver a continuous supply of clean and dry air or nitrogen as required by the process.
Cutting Nozzle Cooling
Laser cutting nozzle also undergoes concentrated thermal stresses due to the laser beam and the impact from the molten material during the cutting process. The cutting nozzles and their mounting structures require cooling to avoid thermal damage. Air nozzles which are cooled by compressed air are contained in laser cutting nozzles that have been integrated with air channels and jet assemblies.
The earlier described chillers and heat exchangers can also be added to the compressed air to supply lower nozzle temperature cooled air. It has to deliver the required airflow through the compressor system with additional pressure losses from the nozzle cooling circuit and must keep component temperatures below critical values.
Optics Cooling and Cleaning
One of the elements of laser cutting head is a number of components such as mirrors and lenses that are used for focusing the laser beam. Purging the lenses is done with a dry and clean air by compressors in a continuous manner to cool the lenses in the cutting head. This keeps unwanted materials from settling on the lenses and ensures that the lenses are in the right condition and cutting edge for the best performance.
Smoke Extraction
During laser cutting, there is a great deal of vaporization and melting that occurs; hence, the production of smoke and fumes. Compressors and ducts are employed closely with highly efficient extractor fans to expel the formed smoke during laser cutting so that it does not pollute the machine tool or contribute to the deterioration of indoor air quality of the workplace.
Material Handling
In addition to this, compressed air is also applied to set the workpiece into the cutting machine and also used to manipulate cut parts after the cutting process is over. This makes it easy to have raw material transported to and finished cut parts out of the laser cutting equipment.
Compressors utilized in laser cutting systems should be capable of delivering clean and dry air or nitrogen at adequate quantity and pressure to support all these operations. If the compressed air is of good quality then this will affect the quality of the cutting and the efficiency of all the equipment being used. Industrial screw air compressors for laser cutting is one the best air compressors that is used in compressing the air for laser cutting.
Part Cleaning
Industrial compressors also provide the compressed air to blow the laser cut parts for cleaning. Cleaning of the material after the laser cutting process is important to reduce the amount of heat affected zone and dross at the edge of the workpiece.
High pressure compressed air is supplied to nozzles located directly over the lower surface of the cut parts and the air jets are directed towards that surface. This air blast helps to remove the chips and scale that has formed on the walls of the narrow kerfs and holes together with the molten metal that is attached after the cut. They utilize up to 10 bar capacity with sufficient airflow to offer the compressed air required at the part cleaning stations of the laser cutting devices.
Motion Control
Laser cutting machines may have their motion control designs that incorporate compressed air. Pneumatic rotary and linear actuators used compressed air and they can provide movement for stages, bridges, and cutting heads.
The compressor system is required to deliver compressed air in sufficient flow rates and meet the pressure requirements to control the motions of the laser cutting machine axes. Other control and protection measures may also be necessary where the actuators are likely to be affected by moisture or contamination by particles.
AI Integration in Laser Cutting Technology
Optimization of Cutting Paths
Artificial Intelligence (AI) is revolutionizing the field of laser cutting by optimizing various aspects of the process, enhancing precision, and improving efficiency. One significant application of AI in laser cutting technology is in the optimization of cutting paths. By using advanced algorithms, AI can analyze complex patterns and determine the most efficient cutting sequences, reducing waste and saving time. This not only enhances the quality of the cuts but also maximizes the use of raw materials. AI-powered software can dynamically adjust the cutting speed and laser power based on real-time feedback from sensors, ensuring consistent quality across different materials and thicknesses.
Predictive Maintenance and Troubleshooting
Moreover, AI plays a crucial role in predictive maintenance and troubleshooting within laser cutting systems. By continuously monitoring the performance of compressors and other critical components, AI can predict potential failures before they occur, minimizing downtime and maintaining productivity. Machine learning models can analyze historical data to identify patterns and anomalies, providing valuable insights for preventive maintenance schedules. This proactive approach ensures that the laser cutting systems operate at peak efficiency, reducing operational costs and extending the lifespan of the equipment.
Enhanced Automation and Performance
As AI technology continues to evolve, its integration into laser cutting processes will further enhance automation, precision, and overall performance, making it an indispensable tool for modern manufacturing.
Conclusion
Compressed air is crucial in the operation of laser cutting machines, and that a consistent and effective supply of it is necessary. From assist gasses, to optics cooling through to part cleaning stations, compressors are required for numerous laser cutting processes.There are so many air compressor for laser engraver but a correct size of the compressor system with a proper level of air treatment is one of the vital components that influence the corresponding productivity and cut accuracy of industrial laser cutting.