For fabricators processing tube and pipe and structural materials, the ability to complete more operations in fewer steps can have a significant impact on production times and overall throughput. Often, the laser cutting operation is just the first stop. Once a part leaves the laser, it may still need to be drilled, tapped, chamfered or machined another way before it is ready for assembly. Each additional operation can mean another transfer of the part to another machine and then another setup.
Mazak’s new FT-250 laser cutting system takes a different approach, combining high-speed fiber laser cutting with machining capabilities in a single machine tool. Whether for facilities performing higher volume production or shops doing high-mix parts, the machine is intended for processing long tube and pipe and structural shapes such as angle iron, C-channel and I-, L- or H-shaped beams.
“The FT-250 is great for the shops looking for a done-in-one type of solution,” says Garrett Peterson, senior applications engineer, Mazak Optonics. “In addition to the laser cutting, they might need to do light machining work, such as chamfering, tapping and pocket boring. We’ve added a spindle to the machine to do the machining work. There’s a rotary unit that functions as an automatic tool changer for the spindle to change out tools.”
The main benefit of this addition is saving time – time for setups and for cutting and machining. Reducing the need to transfer the part between machines is another timesaver. Eliminating the extra handling saves time and labor while reducing the opportunities for errors that can occur when a part is repeatedly handled.
Expanding capabilities
On the laser side, specialized axes expand cutting capability. The programmable B-axis allows the cutting head to tilt, enabling bevel cutting, which is good for weld fit-up and multi-tube assembly. The U-axis provides an additional axis of motion. Rather than requiring the entire part to move, the U-axis allows processing of holes and small features easily with the laser. And, the C-axis controls the part rotation. It synchronizes with the torch’s linear travel to process structural shapes.
On the spindle side, the rotary unit, or auto tool changer, can hold 13 tools. The spindle can retrieve different tools as needed, including those for drilling, tapping and chamfering. Finally, the dual-motion setup means the spindle and laser head are independent of each other, which is another timesaver.
“As the machine is cutting, the spindle can go over and change tooling,” Peterson says. “On previous models, they were on the same gantry so this couldn’t happen. Now, the spindle can change tooling while the laser is still cutting; it doesn’t have to sit idle.”
Making it smart
The FT-250 incorporates a range of automated features that simplify setup and maintain consistency in the process: automatic profiler calibration, nozzle cleaning and focus positioning. The machine also incorporates a camera-based nozzle centering feature. Maintaining alignment between the laser beam and the nozzle is key and it can easily be affected by a part tip-up or head collision.
Traditional methods require the operator to manually check the position of the beam relative to the nozzle. The camera-based system provides a faster way to check the alignment and determine whether the beam is properly centered within the nozzle.
“If a machine doesn’t have this capability, the operator has to put a piece of clear tape or something similar on the nozzle tip and turn the laser on for a moment,” Peterson says. “When they pull it off, they can see if the hole created by the beam is centered within the ring of the nozzle. The laser beam becoming off-center is inherent to the process so the ability to center it quickly and accurately is where the camera comes in handy.”
Long tube and pipe and structural materials are not always perfectly straight. Rectangular tubing, in particular, can have bow or sweep, or curve, that affects its position relative to the centerline.
A new feature on the FT-250 is a high-speed centering system that uses a laser scanner to determine the actual position of the part in relation to the machine’s chuck. The system can then compensate for deviations in the material and adjust the program to correspond with the actual centerline. The system essentially replaces the slower automatic touch probe.
“We can tell the machine that the center of the beam has shifted a bit,” Peterson says. “Now, it can shift the program to match to the center of the part to compensate for those irregularities.”
Helping the user
One final important note is about the changes Mazak has made to the operator interface. The built-in guidance can reduce the amount of experience required to perform routine operations.
“The advancements to the graphical user interface on the center controller really stand out,” Peterson says. “It’s becoming more and more advanced to the point where it’s asking the operator what they want it to do instead of them having to tell it everything. It asks the questions needed so all areas are covered before the machine can go to the next step. ‘Are you prepared? Did you set your nozzle? Did you set the nozzle centering? Did you calibrate it?’ It adds more checks for the operator – more reminders and more pictures. It’s an intelligent machine.”
The benefit is less training time and less experience required. The interface provides prompts, checks and reminders throughout the day.
The long haul
Handling long, heavy tube and pipe and structural materials can itself become a manual production challenge. The FT-250 addresses the issue with automated material handling options, including bundle loading or a conveyor system. This, of course, is an advantage in industries such as oil and gas.
“Citing specific examples, the agriculture industry uses this machine for tapping and so they really appreciate it,” Peterson says. “And the construction industry takes advantage of the tool changer and the high speed of the bundle loader.”
Another emerging area of demand is data center construction. This expansion has created demand for the structural materials used in the racking and support systems found in abundance in data centers.
“We’re currently providing many of our tube lasers to meet the demands of building data centers,” Peterson says, “and we see no signs of that slowing down.”
Ultimately, manufacturers looking to reduce lead times, increase production capacity and make better use of available labor will find a solution in the FT-250’s ability to complete more work in a single setup. Its vast capabilities allow manufacturers processing tube and pipe and structural materials to rethink the traditional ways of production and realize all the timesaving features available today.
From high-speed fiber lasers to laser cutting best practices, you’ll find it all in our archive devoted to lasers.
