co2-laser - fdp. dr.-ing. eckhard beyer.pdf · from catia-files generating the cutting program ......
TRANSCRIPT
sbey:05_10_55_1_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
CO2-Laser
Eckhard Beyer Fraunhofer IWS Dresden
Markus LingnerRofin-Sinar Laser GmbH
sbey:05_10_55_2_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Main application areas of lasers
Today Tomorrow
2D cutting CO2 laser 3D cutting CO2 laser
2D welding CO2 laser3D welding Nd:YAG-laser
Soldering diode laserHardening diode laserCladding diode laser
sbey:05_10_55_3_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision WolfsburgTh
e po
wer
of l
ight
CO2-Slab-Laser
66--SepSep--05 W. 05 W. RathRath
Optional with donut mode
sbey:05_10_55_4_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
3D laser cutting machine with linear drives (company Arnold )
sbey:05_10_55_5_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
3D laser cutting machine with linear drives (company Arnold )
• control: Siemens 840 D
• linear drives: 1FN3
• acceleration: 2 g
• feed velocity: 100 m/min
• positioning accuracy: <0,03 mm
• repetition accuracy: <0,01 mm
• working area: 4,2 m x 2,5 m
sbey:05_10_55_6_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
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_7_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
3D laser cutting of a BMW A-pillar
Video
sbey:05_10_55_8_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Axis configuration of the 3D cutting machine12-axis treatment withsimultaneous double 5 axis-transformation
3D-distance-control inworking area with overlaidfast short-stroke-axis
twin-laser-treatment
4-axis:torque drivesv = 1000 rpm
4-axis:torque drivesvs = 1000 rpm
4-axis:linear drives
v = 100 m/min
4-axis:linear drives
vs = 100 m/min
6-axis:rotary
s
2-axis:toothed belt drives
v = 60 rpm
2-axis:toothed belt drives
vs = 60 rpm
6-axis:linear
3D-cutting machine with
12 axis
s
s
2-axis:spindle drivesv = 30 m/min
2-axis:spindle drivesvs = 30 m/min
control:Siemens 840 D
2-channels
s
sbey:05_10_55_9_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Process chain 3D laser cutting
customer IWS
CO2 laserCO2 laser
Fiber laser
Fiber laser
• Cutting of different materials
• No secondaryprocessingtime
• High dynamic cutting of largeconstruction unitswith excellentpositioningaccuracy
construction unite. g. deep drawing
body prototype
generating thecutting program
with FasTrim from CATIA-files
generating thecutting program
with FasTrim from CATIA-files
3D-geometriesin CATIA-format
• large dimensions
• complex 3D-geometries
• Teach-Innotnecessary
sbey:05_10_55_10_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
140
2
4
6
0 1 2 3 4 5 6 7 8 9 10 11 12 13
penetration (mm)
Wel
ding
spe
ed(m
/min
)
4 kW6 kW
8 kW
Welding of Mild Steel St 52 f=300 mmGas: He
66--SepSep--05 W. 05 W. RathRath
14
12
10
8
sbey:05_10_55_11_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
penetration depth [mm]
0,
2
4
6
8
10
12
14
0 2 4 6 8 10 12 14
wel
ding
spe
ed (m
/min
)
GaussDonut
66--SepSep--05 W. 05 W. RathRath
Welding of Mild Steel St 52 f=300 mm Gas: He
sbey:05_10_55_12_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
2D laser weldingAdvantage of a gaussian mode for thinner laser seams at butt joint welding
Advantage of a donut mode for wider laser seams at overlap welding
66--SepSep--05 W. 05 W. RathRath
sbey:05_10_55_13_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Laser welding of powertrain components
1
1 mm
Process laser powerprocessing speedfocussing parameter
Materialpreheatinginductor geometryfiller wire
Design surface tensionconstructionstiffness
sbey:05_10_55_14_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Trends in layout, construction, function and production of powertrain components
Critical welding applications
cast iron
80-55-6
case hardened
steel4320
case hardened
steel4320
case hardened steel / quenched and tempered steel
cast iron / quenched and tempered steel
cast iron / Cast iron
quenched and tempered steel/ mild steel quenched and
tempered steel1045
sbey:05_10_55_15_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Welding with filler wire
leading position
trailingposition
Video
sbey:05_10_55_16_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
laser beam
cast iron
case hardenedsteel
Problem:
Reasonable production of differentials
Laser beamwelding
Laser beam welding+ filler wire
1 mm 1 mm
sbey:05_10_55_17_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
laser beam
cast iron
case hardenedsteel
Laser beam welding withmaterial adapted filler wire
Problem:
Reasonable production of differentials
Video
sbey:05_10_55_18_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Laser welding production machine
IWS - Patent
sbey:05_10_55_19_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Welding defects by insufficient cleaning of the joint geometryparticle
grease
oil
workpiece
Soiling of the joining area
cleaning area
Laser cleaned
sbey:05_10_55_20_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
particle
grease
oil
workpiece
Soiling of the joining area
cleaning area cleaning area
scanner
CO2 laserlaser power 2,5 kWintensity 106 w/cm²
Laser cleaning
sbey:05_10_55_21_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Main application areas of lasers
Today Tomorrow
2D cutting CO2 laser CO2 laser, (fiber laser)3D cutting CO2 laser fiber laser, (CO2 laser )
2D welding CO2 laser CO2 laser, (fiber laser)3D welding Nd:YAG-laser fiber laser
Soldering diode laser diode laserHardening diode laser diode laserCladding diode laser diode laser
sbey:05_10_55_22_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Trends in layout, construction, function and production of powertrain components
Higher torque at reduced dimensionshigher loading stresseshigher strength materials
restricted weldabilityHigher functional integration
more complicated shapematerials well-tolerable against sensor functions
welding of dissimilar materials
Welding in the finally machined stateminimum heat inputminimum distortionreduced residual stresses
laser welding
sbey:05_10_55_23_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Trends in layout, construction, function and production of powertrain components
Critical welding applications
Industrial solutions
• Laser welding withfiller wire
• Laser induction technologycase
hardened steel4320
cast iron
80-55-6
case hardened
steel4320
quenched andtempered
steel1045
sbey:05_10_55_24_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Solution: Laser beam welding withmaterial adapted filler wire
100
200
300
400
500
600
700
800
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Weg in mm
Här
te H
V 0
,3
100
200
300
400
500
600
700
800
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Weg in mm
Här
te H
V 0
,3
without filler wire with filler wire
ductile zone
case hardened steel4320
cast iron80-55-6
sbey:05_10_55_25_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Laser welding and cleaning machine
Video
sbey:05_10_55_26_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
0
2
4
6
8
10
12
14
0 1 2 3 4 5 6 7 8 9 10
Welding stainless steel f = 200 mmDC 045 4,5 kW Helium
Gauss
penetration depth (mm)
wel
ding
spe
ed(m
/min
)
7,0 m/min
12,0 m/min
Donut
Donut
Gauss66--SepSep--05 W. 05 W. RathRath
sbey:05_10_55_27_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
Laser beam welding with filler wire
leading position
Video
trailingposition
Key-hole opening during laser beam welding with filler wire
sbey:05_10_55_28_bey.ppt
Fraunhofer InstitutWerkstoff- undStrahltechnik
IWS
Forum AutoVision Wolfsburg
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.