How do I determine which cutting method is best for your needs?

In order to determine the best metal cutting method for your process, you will need to conduct a through examination of your production needs. All cutting methods including waterjet cutting, flame cutting, laser cutting etc have their own advantages and disadvantages.

Typical criteria used for most process evaluations should include the following:

1. Type of material that is to be Processed
2. Material Thickness – you will have to determine the range of material thickness to ensure best cutting method for it.
3. Accuracy required in the cutting of stainless steel profiles.
4. Finish required in the material to be cut.
5. Rate of production desired.
6. Cost of technology that will be used for processing.
7. Machine operating costs and machinist skill requirements

Metal cutting by Laser Cutting Machines

Laser cutting is one of the fastest processes that allow metal fabricators to create high-quality parts. The pieces cut by laser cutting fabrication machines require very little, if any, finishing work as the high-powered laser burns, melts or vaporizes away the excess material left in the cutting process.

Two most popular types of laser cutting machines widely in use today are CO2 laser cutting machines and Nd:YAG (neodymium-doped yttrium aluminum garnet) laser cutting machines. CO2 were one of the first gas lasers and are the most common variety of laser cutting machines. These machines have an excellent input output power ratio ranging its efficiency up to 20 percent. Nd:YAG laser machines use a crystal as a lasing medium and are extensively used in manufacturing industry for cutting and welding steel profiles and various alloys.

Benefits of Laser Cutting Machines

1. Laser cutting machines cut metals with a very higher precision.
2. Since the machine never comes in contact with the metal, there is no wear and tear on the equipment and there are less chances of the metal to become contaminated.
3. Laser cutting is faster and more productive. Computer touch screens aid the laser equipment to plot out designs and the machine can cut multiple designs in one run by storing inventory on site.
4. In laser machine cutting, the heat affected zone is kept small, thus reducing the possibility of warped material.
5. Apart from being decently quite, laser profiling and cutting machines are safe too. Most of the laser machines are completely enclosed to prevent any kind of accident.

A few considerations

1. Laser machines do not function well on highly reflective metals like aluminum and copper.
2. Laser machines consume very high level of energy, making it more difficult for conventional metal fabricators to incorporate into its metal fabrication system.
3. Holes created by laser cutting machines are slightly tapered with the hole entry being slightly larger in diameter than the exit.
   
   

Applications, advantages and disadvantages of flame cutting method.

Flame cutting is an important industrial production process suitable especially for materials like carbon and low alloys steel. Using this cutting method, a carbon steel of up to 150mm can be cut with typical tolerances from +/- 1.5mm.

Various applications of flame cutting method.

1. It is used to cut many layers of thin sheets also known as stack cutting to reduce the cost and time of production effectively.
2. Flame cutting is used to groove weld joint metal designs and to prepare the edges of metal plates.
3. It can be used to cut risers, rivets and gates from castings.
4. Flame cutting is also used for salvage work and to pierce slots and holes of different sizes in steel plates.
5. Also used to cut work pieces of small sizes from large metal plates for further usage in production.

Advantages of Flame cutting method.

1. It can cut metals into small shapes and sizes that is otherwise difficult to be machined by other mechanical methods.
2. Equipments used in flame cutting process are portable and can be used effectively for field work
3. Flame cutting machines with multiple torches can cut number of steel profile pieces simultaneously.
4. This process of steel cutting is faster as compared to other mechanical cutting methods.
5. As compared to other mechanical cutting methods, the cost of using flame cutting method is rather low and cost effective.

Disadvantages of flame cutting method.

1. This method is limited to the cutting of steel and cast iron materials only.
2. The dimensional tolerances as compared to other mechanical cutting methods are poor.
3. The heat and red hot slag expelled during this metal cutting method present fire and burn hazards to plant and workers.
4. Proper fume control and adequate ventilation is must for the place of cutting.

Disadvantages of waterjet cutting method.

Among various cutting methods, Waterjet cutting is one of the most useful machining processes that can be readily substituted for many other cutting methods; however, this method too has some limitations to what Steel Profiles it can cut. And for the people dealing in Waterjet Metal Cutting industry, it is necessary to be aware of these limitations. Listed below are some points that will give you a brief description of each.

1. By using waterjet metal cutting method only a limited number of materials can be cut economically. Thus being one of the main disadvantages of waterjet cutting. While it is possible to cut tool steels, and other hard materials, the cutting rate has to be greatly reduced, and the time to cut a part can be very long. Because of this, waterjet cutting can be very costly and outweigh the other advantages that it offers.
2. One more disadvantage of waterjet cutting method is that it is not possible to cut very thick parts with waterjet cutting as there may be problems in maintaining the dimensional accuracy of the metal to be cut. If the part is too thick, the jet may dissipate some, and cause it to steel cut on a diagonal, or to have a wider cut at the bottom of the part than the top. It can also cause a ruff wave pattern on the cut surface.
3. Taper is also a problem with waterjet cutting in very thick materials. Taper is when the Steel Cutter jet exits the part at a different angle than it enters the part, and can cause dimensional inaccuracy. Decreasing the speed of the head may reduce this, although it can still be a problem.

Advantages of using Waterjet cutting method.

Waterjet cutting method is used in many applications and there are number of reasons for which waterjet cutting is preferred over other cutting methods. Here is a list of advantages offered by waterjet cutting technology:

1. No heat id generated in waterjet cutting method. This reason makes this method especially useful for cutting tool steel and other metals where excessive heat may change the properties of the material.
2. The method is quite safe to be used by humans in way that unlike other machining or grinding methods, waterjet cutting does not produce any dust or particles that are harmful if inhaled.
3. A very little material is wasted in warjet cutting method as the kerf width in waterjet cutting is very small.
4. This method can be conveniently used to produce prototype parts very efficiently. An operator can program the dimensions of the part into the control station, and the waterjet will cut the part out exactly as programmed. This is much faster and cheaper than drawing detailed prints of a part and then having a machinist cut the part out.
5. Waterjet cutting can be easily automated for production use.
6. This cutting method does not leave a burr or a rough edge, thus eliminating the need of finishing and grinding of the cut surface.
7. Waterjets machines are much lighter than equivalent laser steel cutters, thus reducing the problems of accelerating and decelerating the robot head, as well as taking less energy.

I will be discussing the disadvantages of the waterjet cutting technology in my next article. So guys keep reading….)

Laser vs Waterjet technology.

Both laser and waterjet metal cutting methods use machines that have a good life expectancy as they don't make direct contact with the work piece during the cutting process also do not use dynamic machining forces. So, when both technologies can do the job, how do fabricators determine which process to use? Understanding a few key factors can help them make the choice.

While choosing between laser and waterjet steel cutting technology, two important factors need to be considered - edge quality and speed.

Thickness and speed: A 0.75 thick section of stainless steel when cut using both the methods reveals the difference in quality (laser at top, waterjet at bottom). The major tradeoff is speed; for a metal sheet as thick as this, a waterjet machine requires nearly 80 percent more time to accomplish the same cut.

Laser technology is well-suited to cut metal parts up to 1⁄2 inches. But they can also cut metals up to 11⁄2 inches thick. On the other hand, waterjets can cut material up to 6 inches thick. Metal cutting with laser machines often have a speed advantage over waterjet machines, however, waterjets can cut through significantly thicker metals, and alternative materials, with ease.

Material and material surfaces: Other than cutting metal sheets and creating steel profiles , lasers can process other materials too, but this doesn't mean they should because on other surfaces than metals laser cutting can result in hazardous chemical releases. For example, on plastics and rubbers laser cutting releases byproducts which are chemically hazardous for the environment. In such cases, waterjet machines steel cutters can easily cut these other materials without hazardous chemical releases.

Material surfaces like that of copper and aluminum are difficult for the lasers to cut because of highly reflective properties of these metals. In such cases the edge quality attained by using waterjet technique is significantly better. Laser cutting technology can be best used on the smooth surfaces rather than textured surfaces as textured surfaces can alter disrupt the beams focus thus altering the flow of assist gas. Waterjet cutting method on the other hand produces smooth cutting irrespective of the metals texture and reflectivity.

A laser performs best on smooth surfaces; textured surfaces can alter the flow of the assist gas and disrupt the beam's focus. A waterjet, on the other hand, doesn't discriminate when it comes to reflectivity or texture.

End product finish: Since waterjet cutting method does not create any heat affected zone, thus it delivers smooth edge finishes eliminating the need for a secondary finish completely. Whereas the heat from laser metal cutting method produces a small heat-affected zone near the cut, which could require secondary finishing depending on the finish requirements.

Determining the best cutting method for your industry.

How will you determine which cutting method best suits your needs and requirements? A simple answer to this question is to conduct a careful examination of your production needs to determine the best cutting method for your process. All metal steel cutting methods like waterjet cutting, flame cutting, laser cutting etc. methods have their distinct advantages and disadvantages. Typical criteria used for most process evaluations include the following points:

1. Type of material to be processed
2. Thickness of the material.
3. Accuracy and finish acquired by using any particular cutting method.
4. Rate at which the production is required
5. Operating Costs and the cost of technology being used.
6. Technical skill Requirements.

Advantages of using a laser cutting method.

There are practically many reasons that will lead you to choose laser cutting method and machines for your industry cutting requirements. Here I have listed a few:-

1. Laser cutting method is very fast as lasers can cut at very high speeds.
2. Many complex designs can be performed by using laser cutting method as there is almost no limit to the cutting path of a laser beam.
3. Metal Cutting by Laser reduces expensive tooling costs or long lead times in many cases.
4. Small diameter holes that cannot be made with other machining processes can easily and quickly be performed with a laser.
5. The laser machine does not have parts that can wear out or become dull or break easily. Thus using this method saves the part replacement costs also.
6. The process is non-contact and non-force, allowing very fragile parts to be cut with little or no support, and the part keeps its original shape from start to finish.
7. A wide range of materials can be cut using lasers producing a high quality cut without any additional process involved.
8. Laser cutting method is quite an effective cutting method with low operating and maintenance costs and maximum flexibility.

Waterjet or Laser - Which cutting method will you choose?

The quality of every finished product depends on the methods and tools used to get the product in that shape. Thus the performance of cutting and profiling methods directly effect particular products or machines overall productivity. Moreover in every machining and manufacturing system one simply cannot ignore the vital role that these metal cutting methods play. Laser cutting and water jet cutting are two commonly known powerful methods that are used to cut through many different types of surfaces or materials. Both these methods have the ability to produce complicated parts of machinery or create beautiful architectural arts.

Since both laser and water jet cutting methods are efficient, how you will determine which one will be the right process for your particular project. Here I have explained a few points that may help you in choosing the right method for your applications.

Laser cutting

Laser cutting technique is an effective cutting method that reduces costly tooling charges without leaving any rough projection on a work piece after drilling or cutting. This cutting method is a highly accurate approach for cutting aluminum, thin steel sheets, carbon steel and Stainless Steel Cutting up to 5/8 inches thick. This laser metal cutting method remarkably increases the cutting speed providing less turn around time and reducing production cost of your architectural applications.

Cutting accuracy acquired by laser cutting technique also makes it easy for the complicated parts to be machined easily. Laser cutting method allows cutting of materials for both short and long production runs and includes no set-up or tooling costs. High part to part repeatability is other guiding factor in choosing laser cutting technique. The method surpasses waterjet cutting method in terms of cost per inch and speed.

Water jet Cutting

This method can also be used to cut a variety of surfaces and materials like plastic, glass steel, copper, aluminum, Kevlar, Lexan, and more. This method has ability to process materials ranging from .001 inches up to 12 inches in thickness.

The precision of waterjet cutting method meets or exceeds that of other cutting methods, especially in terms of cutting thick materials. The method is most suited to cut complex architectural shapes with tight tolerances. The method involves a cut width of about .025 to

If both laser cutting method and waterjet cutting method are put to compete directly with each other, for materials like thin steels, stainless steel, and aluminum, waterjet may be the more expensive method per inch. But waterjet method’s versatility in reducing secondary operations makes it the best option for variety of projects.