Laser: cutting through

January 16, 2015 10:26 am

Lately laser technology has made its way very strongly across many sectors. The laser technique is helping make cutting tool industry more productive, offering reliable results
 Nowadays the cutting tool technology has made valuable advances, especially in the past 10 years which largely is because of newer and newer coating possibilities came into picture. It is observed that the improvisation in overall product is driven by end users’ demand for cutting and machining of harder stiffer alloys of MS and aluminium.
In current scenario, the market requirements are consistently increasing due to environmental and pollution related issues. The issues like reducing the use of lubricant, coolant and also the end users’ never ending demands of cost cutting, reduced cycle times and less maintenance are of highest concern.
Laser technology in cutting tool industryLaser technology is now gaining importance in automobile, fabrication, defence and aerospace, and cutting tool segments. Cutting tool industry uses lasers for both generic and niche processes.
Some laser operations are proving to be very helpful in cutting tool industry. The same are explained by Maulik Patel, Executive Director, Sahajanand Laser Technology Ltd., as follows:• Laser cutting: The flexibility of laser system acts as an important factor to reach the complex geometries even with best quality and at high speed. Laser cutting is now being widely used for pre-processing of the components done with fibre laser cutting which will go for further operation for fine machining or grinding. This saves time and cost for components as well.
• Laser welding: Laser welding processes are much common in industries with high production rate and for those who don’t compromise on quality of welding. Stunning weld quality, fine finish, high-speed, less HAZ and very low thermal distortions are key determinants of laser welding. Laser welding is majorly used on metals namely stainless steel, carbon steel, aluminium and titanium. Bi-metals and alloys as well are preferred to be welded with lasers. Right from microelectronic components to heavy thicker metals, laser welding is versatile enough deliver the best in class results. Bi-metal laser welding of band saw is a budding application.
• Laser marking: Legibility, contrast, permanency, hi-speed operation, very low cost of ownership, flexibility to adapt various marking profiles and contactless process are the key criterion for tooling industry to consider lasers for marking application. Laser marking is used for traceability and branding purpose on carbide tools, drill bits, milling cutters and saw blades. It delivers unmatched performance both in quality and in speed of marking.
• Laser drilling: There are applications of micro machining of some critical components where cutting tool is replaced with laser for drilling or cutting micro holes on critical components for aerospace and defence as well as in medical segment. Highly precise and micron level drilling of fuel injection systems in automobile industry done with lasers is an emerging application.• Other machining processes: Laser operations are now widely used for pre-processing of the components that move towards further operation for fine machining or grinding. In this case, early processing with lasers saves time and cost for components.
“Now laser technology in a cutting tool industry comes up with many inherent advantages. Most laser cutting machines do not need any lubricants for cutting,” points out Naren Shikarkhane, Technical Director, Scantech Laser Pvt. Ltd. “Secondly; harder as well as softer materials are cut at the same speed. In fact harder material such as spring steel gets cut faster than quality MS and with better edge definition.”
The laser as a cutting tool also has taken major steps in its wall plug efficiency making it greener. For example, the wall plug efficiency of cutting lasers has increased from 10 to 30 per cent.
Latest innovations “Lasers are being improved on the aspects of quality of finish and versatility of applications. High speed operation is obviously one of the most important aspects that has been under continuous improvement,” says Mr Patel. “Laser assisted machining is the latest innovation that is catching fast in machine tools industry.”

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