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Five-axis laser and waterjet machining
LAI's manufacturing technologies save time and money
Copyright 1999
Laser and waterjet processing continues to evolve from simple flat cutting to five-axis machining, non-conventional manufacturing services in which LAI Midwest leads the way.
The Minneapolis-based job shop has specialized in waterjet and laser processing since 1992, expanding its capabilities to offer both five-axis waterjet and five-axis laser services. Innovations in five-axis processing make it possible to process components that were difficult or impossible just a few years ago.
Five-axis processing also offers time- and money-saving benefits that include a reduction in tooling investment, elimination of part repositioning and a decrease in multi-stage manufacturing operations.
Five-axis laser processing
One of laser processing's main advantages is its high processing speed. By merging this speed with the maneuverability of five-axis motion, laser processing gains extraordinary flexibility.
"Five-axis laser processing offers total flexibility and throughput that flat cutting systems just can't match," Rick Jackson, LAI Midwest's Laser Operations Manager, said.
A new C02 laser is the latest five-axis workstation LAI Midwest has added to its machining capabilities. The workstation has a power output range of 1,500 to 3,5000 watts and offers .001" accuracy, maximum positioning speed of 1,180 i.p.m. and a Renishaw part location touch probe.
Dual work areas measure 60" by 60" and offer continuous part processing with zero load and unload time. LAI's laser stations can cut round or square tubing up to 30" in diameter with up to 1/2" wall thickness.
The advantages of rotary and five-axis laser processing are clear when faced with machining curved and other difficult-to-machine three-dimensional parts. Intricate components that are hot formed, spun, deep drawn and hydro-formed are ideal for five-axis laser machining, which can drill holes, trim parts, cut slots and machine intricately shaped windows. Ferrous and non-ferrous metals, plastics, and other materials can all be processed by laser.
Five-axis laser processing is ideal for cutting, drilling, welding, heat treating and surface modification. Examples of five-axis laser applications include:
§ Welding lamination stacks for electric motors.
§ Cutting windows into spun aluminum domes.
§ Drilling holes into steel compartments.
§ Cutting contours of three-dimensional components.
Five-axis waterjet cutting
While five-axis laser processing offers superior flexibility, five-axis waterjet machining offers similar advantages. Besides reduces tooling costs, five-axis waterjet processing eliminates repositioning of parts and multi-step processing operations. Some parts simply can not be processed using flat cutting waterjet machines. For example, LAI recently waterjet machined two prototype aluminum helicopter rotor components from a single block of aluminum. Other 3-D parts made by LAI include impeller vanes for nuclear pumps and generators.
LAI's five-axis waterjet stations also specialize in cutting angled slots and holes in curved surfaces such as pipes, tubes and rings for industries ranging from petroleum drilling, lighting manufacturing, and pulp and paper processing. Five-axis processing is ideal for processing flat surfaces too, like cutting tapered slots in titanium plates.
waterjet--a cost-effective machining alternative
The capability and precision of watejet technology have continually improved since waterjets were introduced to manufacturing in the early 1980s. LAI contributed to its technological improvements by documenting processing parameters and developing hybrid waterjet systems by modifying current components available in the industry.
An abrasive waterjet can cut almost any material, including plastics, composites and laminates. Aluminum, steel and titanium can be cut up to 18 inches thick.
Motion-controlled machines transport the jet nozzles along programmed paths to cut complex contours with positional tolerances of +/- .001". waterjet cutting leaves a burr-free surface, and since the tool doesn't contact the material and produces virtually no heat, distortion-free cutting is achieved in even the thinnest of materials.
Abrasive waterjet cutting never hardens metals or leaves re-cast layers, something other machining methods such as plasma and electrical discharge machining can do. The abrasive waterjet process never changes the metallurgy of any alloy.
waterjets enable close nesting of parts, maximize material usage and eliminate secondary operations. Abrasive waterjet cutting cuts with a narrow kerf or width of cut equal to that of the inside diameter of the focusing tube.
Saving time and money
One of the main advantages of waterjet processing is its ability to save time and money by roughing out parts before final machining. Abrasive waterjet cutting and drilling serves as a cost-effective means of processing exotic metal and composite materials.
Tooling for abrasive waterjet cutting is usually simply and quickly made. In most cases, tooling is used to hold material flat or off a referenced edge.
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LAI East
1110 Business Parkway S.
Westminster, MD 21157
410-857-0770
410-857-0774 Fax
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LAI Midwest
7645 Baker St. N.E.
Minneapolis, MN 55432
763-780-0060
763-784-4740 Fax
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LAI Southwest
4814 S. 33rd St.
Phoenix, AZ 85040
602-304-1160
602-304-1612 Fax
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Southwestern Laser
975 W. Grant Road, Suite 151
Tucson, AZ 85705
520-807-0433
520-807-0437 Fax
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