The traditional method of sheet metal punching is to use a punch press to press, relying on external hard force directly acting on the surface of the work piece, which can easily cause low accuracy and multiple edge punctures. But the emergence of laser cutting technology has changed the current disadvantageous situation, and more and more processing companies are choosing lasers to cut round holes.

The laser cutting machine has a smooth cross-section and the diameter can be changed at any time, with high operational flexibility. However, it has modern processing methods and requires a skilled operator. Improper operation can result in irregular round.

1. Four major factors affecting the cutting accuracy of laser cutting machines

1) The size of laser coagulation in the laser generator

If the light spot is small after aggregation, the cutting accuracy is high, and the gap after cutting is also small. This indicates that the fiber laser cutting machine has high precision and good quality. But the beam emitted by the laser is conical, so the cut gap is also conical. Under these conditions, the thicker the work piece, the lower the accuracy, resulting in a larger cutting seam.

2) Accuracy of the workbench

If the precision of the fiber laser cutting machine worktable is high, the cutting accuracy will also increase accordingly. Therefore, the accuracy of the workbench is also an important factor in measuring the accuracy of the laser generator.

2) Laser beam condenses into a cone shape

When cutting with a fiber laser cutting machine, the laser beam is tapered downwards. If the thickness of the work piece being cut is large, the cutting accuracy will decrease, resulting in larger gaps.

3) Different cutting materials

It will also affect the accuracy of fiber laser cutting machines. In the same situation, the accuracy of cutting stainless steel and cutting aluminum with fiber laser cutting machine will be different. The cutting accuracy of stainless steel will be higher, and the cutting surface will also be smoother.

2. The reason for the problem of laser cutting round holes

1) Light beam quality issue

Poor light beam quality is one of the common reasons for non-round small holes, especially when cutting thinner materials, where higher requirements are placed on light beam quality. At this point, it is necessary to check whether the output of the laser and the optical path system are normal.

2) Spot size issue

If the spot size of the laser machine is not appropriate, it can also cause the small hole to be non-round. In this case, it is necessary to adjust the light spot.

3) Cutting speed issue

Cutting too fast can also cause small holes to be non-round, and it is necessary to reduce the cutting speed.

4) Gas pressure issue

Laser cutting requires spraying gas to blow away dust and gas from the cutting area. If the gas pressure is unstable, it can cause the small hole to be non-round.

5) Loose fastening screws of cutting head

During the cutting process, external forces acting on the cutting head may cause the fastening screws to loosen. If the screw is loose, the cutting head will shake, causing the cutting to not be round.

6) Loose cutting head back plate

The back plate of the cutting head is an important component that supports the cutting head. If the back panel becomes loose, the cutting head will lose stable support, causing it to shake and cut non-round during the cutting process.

7) The clearance between the X or Y-axis gear and the rack is too large

The X or Y-axis gear and rack are important components in the cutting process. If there is a gap between the gear and the rack, it will cause power imbalance during the cutting process, resulting in non-round cutting.

8) Gearbox problem

The reducer is a key component for controlling cutting speed. If the gearbox malfunctions or has design defects, it will cause power imbalance during the cutting process, resulting in non- round cutting.

9) Issues with guide rails and sliders

X. The Y and Z-axis guide rails and sliders are important components for supporting and guiding the cutting head. If the guide rail and slider are loose or worn, or if the steel ball on the slider drops directly, it will cause unstable movement of the cutting head, resulting in non- round cutting.

Click here to know other laser cutting problems and solutions:

How To Prevent Burrs In Laser Cutting?

FAQ: Laser Cutting Reflective Metal Copper and Brass

Laser Cutting Machine Model And Parameters [Power & Plate Thickness Table]

Laser Cutting Quality Control: Important Factors And Solutions

3. Solution for laser cutting round holes

- Check the optical system to ensure stable output power and that the spot quality meets the requirements.

- Check if the spot size is appropriate and replace it with a spot of the appropriate size.

- Reduce the cutting speed to ensure sufficient contact time between the material and the light spot during the cutting process.

- Check if the gas pressure is stable and ensure sufficient gas injection.

- Check if the cutting tool is severely worn and if the cutting surface is flat.

- Check the fastening screws and back plate. If the cutting is not round, first check whether the fastening screws and back plate of the cutting head are loose. If looseness is found, it should be tightened immediately to ensure the stability of the cutting head.

- Check the gears and racks. If the cutting is not round, check whether there is any gap between the X or Y axis gears and racks. If the gap is too large, the gears and racks should be repaired or replaced immediately. At the same time, it is necessary to check whether there are design defects in the gearbox. If the problem is caused by design defects, the design needs to be improved.

- Check the guide rails and sliders. The X, Y, Z axis guide rails and sliders are important components for supporting and guiding the cutting head, so they need to be regularly inspected for looseness or wear. If looseness or wear is found, tighten or replace the components immediately. At the same time, it is necessary to check whether the steel ball on the slider has fallen off. If it is found to have fallen off, the steel ball should be replaced immediately.

- Maintenance: In order to avoid problems such as uneven cutting of laser cutting machines, it is necessary to regularly maintain the equipment. This includes routine operations such as cleaning, lubrication, and inspecting fasteners. At the same time, it is necessary to inspect and maintain the hydraulic and pneumatic systems of the equipment to ensure its normal operation.

In short, there are many reasons why laser cutting machines cannot cut round, and we need to gradually investigate and conduct self inspection. During normal use, it is necessary to regularly inspect and maintain the equipment to ensure its normal operation. Only in this way can we improve production efficiency and product quality, and create more economic benefits for the enterprise.