For decades, laser cutting technology has enabled creative processing of a wide range of tubes, angle iron, c-channel, I-beam and special extrusion profiles. Manufacturers use lasers to produce delicate tubes for office furniture, cut heavier tubes for fitness equipment and process large profiles for agricultural needs.
Tube cutting machines meet manufacturers’ needs for high-speed production with a solid-state laser and a broad range of processing capabilities. One laser tube cutting machine, TRUMPF’s TruLaser Tube 7000 fiber, for example, can cut tubes and profiles with diameters of up to 10 in. and material as thick as 0.625 in.
Laser tube cutting machines offer manufacturers a solid alternative to conventional sawing, drilling and milling, and laser cutting can save time and manual labor costs. Manufacturers that switch from sawing or other traditional processes to laser cutting are often astounded by the dramatic productivity increases that result. One furniture manufacturer realized a double-digit improvement in production by adding a laser tube cutter to its shop.
For other companies, incorporating laser tube cutting capabilities makes it possible to expand their customer base and industries served. Some of the most recent innovations in laser tube cutting technology even further decrease the need for additional part processing and incorporate automation that can reduce labor requirements.
Cutting secondary processing
Because lasers can be used to trim tubes and to cut holes as well as complex contours during a single work cycle, laser cutting can reduce the number of production steps needed and shorten the overall process chain. For example, TRUMPF laser tube cutting machines can create high-quality bevel cuts up to 45 degrees, which eliminates the need for a manual beveling operation to be done after laser cutting.
Beyond beveling, additional time-consuming manual processes can also be eliminated through laser cutting. Special options enable laser tube cutting technology to carry out processes such as friction drilling, drilling, thread cutting and form tapping. Because the laser tube cutting machine takes care of these processes during the cutting operation, parts require fewer secondary operations. A reduction in manual work can translate into faster production and less waste as a result of fewer human errors.
Downstream processes are also simplified through innovative design features made possible by the laser. Laser technology can be used to create tubes designed with plug-in features or snap-lock connections, as well as micro- or nano-joints that facilitate assembly, make it easier to bend parts by hand and reduce the amount of welding needed.
Easier tube cleaning
Laser cutting is characterized by its productivity, flexibility and high quality, but the process can result in metal slag spatter deposited inside the tube. Fabricators often must manually remove any spatter, which can be a laborious and time-consuming task. This can be particularly important for manufacturers in the furniture, medical, agricultural, high-end automotive and other industries that have stringent requirements regarding aesthetics or function. For instance, an oil cylinder must have a clean interior to prevent contamination.
Fortunately, a new solution reduces the spatter adhesion and makes it easier to clean inside the tube. TRUMPF’s new Spatter Guard technology simplifies the task of keeping the inner surfaces of tubes spatter-free.
Mounted on the tube laser cutting unit, the Spatter Guard travels through the tube during the loading process and automatically applies an even mist of water-based anti-spatter to the inner surfaces. The protective coating prevents spatter from building up inside the profile and makes it easier to clean the finished tube. While the machine is cutting the first tube, Spatter Guard is busy preparing the next tube for cutting.
This makes life easier for workers, reduces the need for post-processing and improves the quality of the inside surfaces. Spatter Guard is available on TRUMPF’s TruLaser Tube 3000, 5000 and 7000 fiber machines.
Automation turbocharges
Compared with many other technologies, laser tube cutting can require significant operator involvement. Laser tube cutting machines are highly productive, which means a production worker needs to be available at regular intervals to remove and sort the cut tubes. Many companies have difficulty finding enough skilled workers, especially for physically demanding tasks. And because cut tubes tend to be large and unwieldy, workers are often reluctant to take on this job. TRUMPF has introduced an automated unloading system to help solve this dilemma.
Automated laser tube cutting starts with the production plan, which the operator loads into the machine’s software. Next, the laser tube cutting machine requests the raw material, measures the loaded tubes, automatically carries out part nesting, cuts the required parts to the exact size and then issues instructions for the subsequent steps. The conveyor belt guides the cut tubes onto the unloading section for manual removal or into the automated system’s separate safety enclosure.
From there, the parts can be automatically removed and sorted by a robot or other integrated handling device. The robot, having already received information on the part to be removed, including the desired storage location, activates an appropriate gripper, picks up the part and stacks it in the designated pile. Users can still unload parts manually, if needed.
Improved capacity utilization
Automated loading systems that move raw material directly from storage and automatically load it into the machine have been on the market for some time. But new automated unloading is the final link in the processing chain. Automated unloading systems are a particularly desirable choice for medium and high-volume manufacturers, but they are for job shops as well. Every step in the tube fabrication process can be automated and coordinated now, including laser tube cutting.
Automated part removal saves time and makes life easier for workers. Manufacturers find that automation on the shop floor not only takes the strain off their workers, but also makes their company more attractive to potential new recruits. Instead of having to remove one cut tube after the next, the machine operator can spend their time on other tasks.
By taking over these previously manual tasks, automation allows the operator to work on two machines at the same time without feeling rushed or overloaded. Automated unloading also increases capacity utilization by enabling the machine to produce parts throughout the night without additional staff onsite and reduces the possibility of errors because the automated system always stacks finished parts in the correct location and never mixes them up.
Innovative technology for laser tube cutting saves time, additional processing and manual labor costs. Fabricators are now able to reduce their need to run secondary operations, can keep the inside of tubes “spatter free” and can automate the whole laser tube cutting process from material to stacked finished part.
