CO 2 -Laser. Eckhard Beyer Fraunhofer IWS Dresden. Markus Lingner Rofin-Sinar Laser GmbH. Forum AutoVision Wolfsburg. IWS Fraunhofer Institut
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1 CO 2 -Laser Eckhard Beyer Fraunhofer Dresden Markus Lingner Rofin-Sinar Laser GmbH sbey:05_10_55_1_bey.ppt
2 Main application areas of lasers Today Tomorrow 2D cutting 3D cutting 2D welding 3D welding Soldering Hardening Cladding CO 2 laser CO 2 laser CO 2 laser Nd:YAG-laser diode laser diode laser diode laser sbey:05_10_55_2_bey.ppt
3 CO 2 -Slab-Laser The power of light 6-Sep-05 W. Rath Optional with donut mode sbey:05_10_55_3_bey.ppt
4 3D laser cutting machine with linear drives (company Arnold ) sbey:05_10_55_4_bey.ppt
5 3D laser cutting machine with linear drives (company Arnold ) control: linear drives: acceleration: feed velocity: positioning accuracy: repetition accuracy: working area: Siemens 840 D 1FN3 2 g 100 m/min <0,03 mm <0,01 mm 4,2 m x 2,5 m sbey:05_10_55_5_bey.ppt
6 3D laser cutting of a BMW A-pillar cutting parameter material: DC04, 1,5 mm zinc coated cutting velocity: 10 m/min positioning velocity : 20 m/min laser power: 1500 W focal length: 127 mm (5 ) result: cutting time: 91 s Video sbey:05_10_55_6_bey.ppt
7 3D laser cutting of a BMW A-pillar Video sbey:05_10_55_7_bey.ppt
8 12-axis treatment with simultaneous double 5 axistransformation 3D-distance-control in working area with overlaid fast short-stroke-axis twin-laser-treatment 3D-cutting machine with 12 axis Forum AutoVision Wolfsburg Axis configuration of the 3D cutting machine 6-axis: rotary 6-axis: linear 4-axis: 4-axis: torque torque drives drives v v s = = rpm rpm s 2-axis: 2-axis: toothed toothed belt belt drives drives v v s = = rpm rpm s 4-axis: 4-axis: linear linear drives drives v v s = = m/min m/min s 2-axis: 2-axis: spindle spindle drives drives v v s = = m/min m/min s control: Siemens 840 D 2-channels sbey:05_10_55_8_bey.ppt
9 Process chain 3D laser cutting customer large dimensions complex 3Dgeometries Teach-In not necessary Cutting of different materials No secondary processing time High dynamic cutting of large construction units with excellent positioning accuracy construction unit e. g. deep drawing body prototype 3D-geometries in CATIA-format generating generating the the cutting cutting program program with with FasTrim FasTrim from from CATIA-files CATIA-files CO CO 2 laser 2 laser Fiber Fiber laser laser sbey:05_10_55_9_bey.ppt
10 Welding speed (m/min) Welding of Mild Steel St 52 f=300 mm Gas: He 4 kw 6 kw 8 kw penetration (mm) 6-Sep-05 W. Rath sbey:05_10_55_10_bey.ppt
11 14 Welding of Mild Steel St 52 f=300 mm Gas: He welding speed (m/min) Donut Gauss 0, penetration depth [mm] 6-Sep-05 W. Rath sbey:05_10_55_11_bey.ppt
12 2D laser welding Advantage of a donut mode for wider laser seams at overlap welding Advantage of a gaussian mode for thinner laser seams at butt joint welding 6-Sep-05 W. Rath sbey:05_10_55_12_bey.ppt
13 Laser welding of powertrain components Process laser power processing speed focussing parameter 1 Material preheating inductor geometry filler wire 1 mm Design surface tension construction stiffness sbey:05_10_55_13_bey.ppt
14 Trends in layout, construction, function and production of powertrain components Critical welding applications case hardened steel / quenched and tempered steel case hardened steel 4320 cast iron cast iron / quenched and tempered steel cast iron / Cast iron quenched and tempered steel/ mild steel case hardened steel 4320 quenched and tempered steel 1045 sbey:05_10_55_14_bey.ppt
15 Welding with filler wire leading position trailing position Video sbey:05_10_55_15_bey.ppt
16 Problem: Reasonable production of differentials Laser beam welding Laser beam welding + filler wire case hardened steel laser beam 1 mm 1 mm cast iron sbey:05_10_55_16_bey.ppt
17 Problem: Reasonable production of differentials Laser beam welding with material adapted filler wire case hardened steel laser beam cast iron Video sbey:05_10_55_17_bey.ppt
18 Laser welding production machine sbey:05_10_55_18_bey.ppt - Patent
19 Soiling of the joining area particle grease oil Welding defects by insufficient cleaning of the joint geometry Laser cleaned workpiece cleaning area sbey:05_10_55_19_bey.ppt
20 Soiling of the joining area particle grease oil Laser cleaning CO 2 laser laser power 2,5 kw intensity 10 6 w/cm² scanner workpiece cleaning area cleaning area sbey:05_10_55_20_bey.ppt
21 Main application areas of lasers Today Tomorrow 2D cutting CO 2 laser CO 2 laser, (fiber laser) 3D cutting CO 2 laser fiber laser, (CO 2 laser ) 2D welding CO 2 laser CO 2 laser, (fiber laser) 3D welding Nd:YAG-laser fiber laser Soldering diode laser diode laser Hardening diode laser diode laser Cladding diode laser diode laser sbey:05_10_55_21_bey.ppt
22 Trends in layout, construction, function and production of powertrain components Higher torque at reduced dimensions higher loading stresses higher strength materials restricted weldability Higher functional integration more complicated shape materials well-tolerable against sensor functions welding of dissimilar materials Welding in the finally machined state minimum heat input minimum distortion reduced residual stresses laser welding sbey:05_10_55_22_bey.ppt
23 Trends in layout, construction, function and production of powertrain components Critical welding applications Industrial solutions Laser welding with filler wire Laser induction technology case hardened steel 4320 cast iron case hardened steel 4320 quenched and tempered steel 1045 sbey:05_10_55_23_bey.ppt
24 Solution: Laser beam welding with material adapted filler wire Härte HV 0, Weg in mm case hardened steel 4320 without filler wire Härte HV 0, ductile zone Weg in mm with filler wire cast iron sbey:05_10_55_24_bey.ppt
25 Laser welding and cleaning machine Video sbey:05_10_55_25_bey.ppt
26 14 Welding stainless steel f = 200 mm DC 045 4,5 kw Helium welding speed (m/min) Donut Gauss 12,0 m/min 7,0 m/min penetration depth (mm) Donut Gauss 6-Sep-05 W. Rath sbey:05_10_55_26_bey.ppt
27 Laser beam welding with filler wire leading position trailing position Video Key-hole opening during laser beam welding with filler wire sbey:05_10_55_27_bey.ppt
28 3D laser cutting of a BMW A-pillar Step 4: simulation Kollisionstest des Schneidkopfes Einsatz der Bereinigungsoperationen - Joggen - Interpolieren - C-Achsoptimierung -Events - Kreise über 3 Pkt. sbey:05_10_55_28_bey.ppt
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