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Redsail Technology Co.,Ltd

Optimizing 1000W Fiber Laser Settings for Stainless Steel Sheets

» post_parent) {?>Optimizing 1000W Fiber Laser Settings for Stainless Steel Sheets » Optimizing 1000W Fiber Laser Settings for Stainless Steel Sheets

Optimizing a 1000W fiber laser for cutting stainless steel sheets requires precise tuning of parameters like laser power, cutting speed, focus position, auxiliary gas, and nozzle configuration. Below is a step-by-step guide based on industry best practices and technical insights from the knowledge base:


1. Key Parameters to Optimize

a. Laser Power

  • Recommended Setting: Use 80–100% of the maximum power (800–1000W) for stainless steel. Higher power ensures sufficient energy to overcome the material’s high reflectivity and thermal conductivity.
  • Caution: Avoid excessive power (e.g., >100%) to prevent burning, warping, or damaging the material.

b. Cutting Speed

  • General Rule:
  • Thin Sheets (≤3mm): Use 20–30 m/min for clean, high-speed cuts.
  • Medium Sheets (3–6mm): Adjust to 15–25 m/min to balance speed and precision.
  • Thicker Sheets (6–10mm): Reduce to 10–15 m/min to ensure full penetration and minimize dross.
  • Testing: Start with lower speeds for thicker materials and gradually increase while monitoring cut quality.

c. Focus Position (Negative vs. Positive Focus)

  • Negative Focus (focus point below the material surface):
  • Enhances melt pool stability and reduces heat-affected zones (HAZ).
  • Ideal for stainless steel to prevent oxidation and achieve smoother edges.
  • Recommended Offset: -0.5 to -1.5 mm (adjust based on material thickness).
  • Positive Focus (focus point above the material):
  • Less common for stainless steel but may be used for thin sheets (<1mm) to improve surface finish.

d. Auxiliary Gas

  • Gas Type:
  • Nitrogen (N₂): Prevents oxidation, leaving a clean, stainless-steel-colored edge.
  • Oxygen (O₂): Increases cutting speed but results in oxidized (blackened) edges.
  • Air: Cost-effective but produces lower-quality cuts (yellowish edges).
  • Gas Purity:
  • Nitrogen: ≥99.995% for high-quality, oxidation-free cuts.
  • Oxygen: ≥99.999% for thick plates.
  • Gas Pressure:
  • Thin Sheets (≤3mm): 1–2 bar.
  • Medium Sheets (3–6mm): 2–3 bar.
  • Thicker Sheets (6–10mm): 3–4 bar (ensure nozzle and system can handle higher pressure).

e. Nozzle Diameter

  • Selection:
  • 3–6mm Sheets: Use a 1.0–1.2mm diameter nozzle for precise gas flow and molten material removal.
  • 6–10mm Sheets: Upgrade to a 1.5–2.0mm nozzle to increase gas volume and reduce dross.
  • Check for Damage: Ensure the nozzle is undamaged and has a smooth, circular opening. Replace if worn or clogged.

f. Cutting Height

  • Ideal Range: 0.8–1.2mm above the material surface.
  • Adjustment: Use the blue spark method (as described in [7]) to locate the focal point.
  • Remove the nozzle, blow air, and move the laser head vertically until blue sparks peak—this indicates the optimal focus.

2. Step-by-Step Optimization Process

  1. Preparation
  • Clean the material surface to remove oils, rust, or coatings.
  • Ensure the laser head is aligned and the nozzle is undamaged.
  1. Initial Setup
  • Set the laser power to 80% and cutting speed to 20 m/min for a 3mm stainless steel sheet.
  • Use a 1.0mm nozzle with nitrogen at 2 bar.
  1. Focus Adjustment
  • Perform a blue spark test to locate the focal point.
  • Adjust the focus to -1 mm (negative focus) for optimal melt pool control.
  1. Test Cuts
  • Cut a test sample and inspect for:
    • Smooth edges with minimal dross.
    • No oxidation (if using nitrogen).
    • Uniform cut width (typically 0.5mm for 1000W lasers).
  1. Parameter Tuning
  • If Dross Forms:
    • Increase gas pressure by 0.5–1 bar.
    • Slightly lower the focus (e.g., from -1 mm to -1.5 mm).
  • If Edges Are Rough:
    • Decrease cutting speed by 5–10%.
    • Check nozzle alignment and gas purity.
  • If Burn Marks Appear:
    • Reduce laser power to 70–80%.
    • Increase cutting speed to avoid heat accumulation.
  1. Advanced Adjustments
  • For thicker sheets (6–10mm):
    • Use a 1.5mm nozzle and 3 bar nitrogen pressure.
    • Reduce speed to 10–15 m/min and lower the focus to -1.5 mm.
  • For thin sheets (<3mm):
    • Increase speed to 30 m/min and use a 1.0mm nozzle.

3. Common Issues & Solutions

ProblemCauseSolution
Dross FormationInsufficient gas pressure or focusIncrease gas pressure by 0.5–1 bar; adjust focus to -1.5 mm.
Oxidation (Black Edges)Using oxygen instead of nitrogenSwitch to nitrogen gas (≥99.995%).
Rough EdgesLow cutting speed or misalignmentIncrease speed by 5–10%; realign nozzle and check focus.
Burn MarksExcessive power or slow speedReduce power to 70–80%; increase speed to disperse heat.

4. Safety and Maintenance Tips

  • Cooling System: Ensure the water chiller maintains a stable temperature (20–30°C) to prevent laser tube overheating.
  • Lens and Nozzle Cleaning: Clean the focusing lens and nozzle regularly to avoid contamination affecting beam quality.
  • Gas Cylinder Safety: Secure gas cylinders and monitor pressure gauges to prevent leaks.
  • Workpiece Fixation: Clamp the material securely to avoid vibrations that may disrupt the cut path.

5. Example Settings for 1000W Fiber Laser

Material ThicknessLaser PowerSpeedFocusGas TypeNozzle DiameterGas Pressure
2–3mm Stainless Steel800–900W25–30 m/min-1 mmNitrogen1.0 mm2 bar
4–6mm Stainless Steel900–1000W15–20 m/min-1.2 mmNitrogen1.2 mm3 bar
8–10mm Stainless Steel950–1000W10–12 m/min-1.5 mmNitrogen1.5 mm4 bar

By following these guidelines and conducting iterative test cuts, you can achieve high-quality, efficient cuts on stainless steel sheets using a 1000W fiber laser. Always prioritize safety and regular maintenance to prolong equipment lifespan and ensure consistent performance.

 
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