Laser Welding A New Tool for Metal Fabricators. Tim Morris Technical Sales Manager TRUMPF Laser Technology Center

Transcription

1 Laser Welding A New Tool for Metal Fabricators Tim Morris Technical Sales Manager TRUMPF Laser Technology Center

2 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 2

3 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 3

4 Motivation 1. Elimination of Post Processing Steps 2. Weight Reduction COST SAVINGS 4

5 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 5

6 Laser The Universal Tool for Welding HF MIG TIG EB EB Plasma Seam welding MIG MIG EB MIG Spot welding TIG TIG Laser welding Narrow weld seam Min. heat affected zone Little metallurgic effects on the material Little distortion No filler material required High process speed Non-contact No wear 6

7 Laser Power Density Penetration Depth [mm] Thermal Conduction Welding: up to 90% of the laser power is reflected by the metal surface Threshold Intensity plasma shielding Deep Penetration / Key-Hole Welding: up to 90% absorption Power Density [W/cm 2 ] 7

8 Principle of Laser Welding Heat Conduction Welding Penetration Welding Sheet Thickness < Penetration <

9 Laser Welding in Sheet Metal Manufacturing 9

10 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 10

11 1. Weight Reduction: Cross Member Material Mild Steel Thickness Laser Welding Strategy Wire Feed Shield Gas He 11

12 2. Elimination of Post Processing : OLYMPUS Display Enclosure Material Mild Steel Thickness Laser Welding Strategy Edge Weld (30 linear weld) No Shield Gas Courtesy of H.P. Kaysser 12

13 2. Elimination of Post Processing : OLYMPUS Display Enclosure 40 Production time in [min] min Laser welding 2 min 3 min 8 min MIG welding 3) Strainghtening 2)Grinding 1) Welding 13

14 2. Elimination of Post Processing : OLYMPUS Display Enclosure Manual welding Welding time (manual $73/hour) Grinding (manual $63/hour) Straightening Sum 8 Min 3 Min 2 Min $9.73 $3.15 $2.09 $14.97 Laser welding Welding time (automated $182 /hour) Incl. Load and un-load Straightening Grinding Savings ($) Savings (%) 3 Min $9.10 None None $ % 14

15 2. Elimination of Post Processing : HDM Printing Press Enclosure Material Mild Steel Thickness / Laser Welding Strategy Edge Weld/ Fillet Weld No Shield Gas Courtesy of H.P. Kaysser 15

16 2. Elimination of Post Processing : HDM Printing Press Enclosure 40 Production time in [min] min Laser welding 3 min 8 min MIG welding 1) Welding 2)Grinding 16

17 2. Elimination of Post Processing : HDM Printing Press Enclosure Manual Welding Welding time (manual $73/h ) Grinding (manual $63/hour) 8 Min 3 Min $9.73 $3.15 Sum $12.88 Laser Welding Welding time (automated $182/h) Grinding (manual) 2 Min $6.07 non Savings ($) $6.81 Savings (%) 53% 17

18 2. Elimination of Post Processing : Register Enclosure Material Stainless Steel Thickness Laser Welding Strategy Heat Conduction Welding Shield Gas He 18

19 2. Elimination of Post Processing : Register Enclosure 40 Production time in [min] min ca. 30 min. 24 min 10 min 3 min 3 min 2 min 2 min Laser welding MIG welding 4) Grinding and cleaning 3) Welding (with fixture) 2) Bending 1) Cutting out the blank Example: Housing 16 x24 x10 19

20 2. Elimination of Post Processing : OLYMPUS Display Enclosure Manual welding Welding time (manual $73/hour) Grinding (manual $63/hour) Sum 10 Min 24 Min $12.17 $25.20 $37.37 Laser welding Welding time (automated $182/hour) Incl. Load and un-load Straightening Grinding Savings ($) Savings (%) 4 Min $12.13 Non Non $ % 20

21 2. Elimination of Post Processing : TRUMPF CO 2 Resonator Cover Material Aluminum Thickness Laser Welding Strategy Edge Weld (~ 240 ) Argon Shield Gas Courtesy of H.P. Kaysser 21

22 2. Elimination of Post Processing : TRUMPF CO 2 Resonator Cover 450 Production time in [min] MIG welding -24% Post Processing Manual Welding ( MIG) YAG-Laser Welding Fixture Costs (3 Years) Bending Straightening Punching/Laser Cutting Laser welding Cost Reduction: $ / Cover 22

23 1. Weight Reduction: Exhaust Case Turbo Prop Material Ni-Alloy 90% Sheet Metal Construction Laser Welding Strategy Argon Shield Gas Courtesy of ARCOR 23

24 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 24

25 Keys to Success 1.Design Phase 2.Part Preparation 3.Fixturing 25

26 The First Key to Success - Laser-Friendly Design Joint design 26

27 The First Key to Success - Laser-Friendly Design Use of joining aids embossments 27

28 The First Key to Success - Laser-Friendly Design Compensation of manufacturing tolerances Toler. compensat. Toler. compensat. 28

29 The Second Key to Success Part Preparation Machined, Laser cut, Punched Right-angled Clean (no oil, scale, rust) Oxide free Dross and burr free 29

30 The Third Key to Success Fixturing Inexpensive sheet metal parts Light and sturdy Adjustable Reusable Components 30

31 The Third Key to Success Fixturing 31

32 The Third Key to Success Fixturing 32

33 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 33

34 Robotic Cell Configuration - Layout 34

35 Robotic Cell Configuration - Layout 35

36 Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key s to Success Robotic Cell Configuration Summary 36

37 Summary Laser welding is an established process suitable for both CO 2 and solid-state lasers Tight tolerance requirements can be met with modern laser cutting and punching machines and press brakes and is critical to the success of laser welding in sheet metal Welding fixtures can be produced economically from laser cut sheets or, wherever possible, integrated into the part itself through designs suitable for laser welding Laser welding in sheet metal manufacturing opens up great cost savings for the right applications 37

38 Target Applications Look For Sheet metal applications < thick, currently arc welded Significant amounts of post-weld processing (grinding, straightening, etc ) Precision laser cutting, bending capability, and precision tooling capability must be in place Stainless Steel components typically have the quickest payback 38

39 Thank you Tim Morris General Manager TRUMPF Laser Technology Center