Photo 1: Hole cutting quality and speed are improved while laser lens life is extended by 22% at TruCut Fabricators. Geoff Jones, laser production manager (pictured at right with Mate PEAK lens in right hand), and Jay Hodges, Mate sales engineer (left), are holding laser processed parts using the Mate PEAK lens. |
Photo 2: Mate PEAK lenses offer peak performance in a broad range of CO2 cutting applications requiring as much as 6000watts and as little as 1000 watts. Lens absorption for Mate is 30-40% below standard lenses (= 0.15%) for longer lens life. |
PHOTO 3: Laser hole quality is consistent well beyond the 656 hours tested on the Mate PEAK lens. Parts like those pictured were produced in TruCut's test. |
PHOTO 4: TruCut's industrial blower housings are laser processed using the Mate PEAK lens. Hole and edge quality was improved significantly by switching to a Mate PEAK laser lens. |
Forest, Virginia: TruCut Fabricators is a full service metal fabricator utilizing Value Engineering and Focused Project Management to deliver the highest quality product at the lowest price. To accomplish these goals, the company periodically tests new products against existing ones in order to improve its fabricating processes.
In the area of CNC laser cutting, the company recently completed a test of the new Mate PEAK low absorption laser lens with a lens it had previously used in its Trumpf TLF 3000 CO2 laser system. TruCut utilizes this machine for prototype, long and short runs to fabricate components for industrial blower housings, transformer housings, electronic cabinetry and general metal fabricating. (Photos One and Two)
Materials include .750 inch thick carbon steel, .500 inch thick stainless steel, and .187 inch thick aluminum and galvanized steel. A laser is used to cut material to size and to produce various diameter holes and other part features. Hole consistency part-to-part is a key consideration in TruCut's laser operations. (Photos Three and Four)
"Getting consistent hole quality is Important to us and our customers," reports Geoff Jones, laser production manager of TruCut Fabricators. "We pay careful attention to it because of the wide range of materials, different thicknesses and hole sizes that we work with. We constantly look for ways to improve our laser process quality and feed rates. When Mate's sales engineer, Jay Hodges, proposed a four week study using the new PEAK lens, to see what it would do to improve our laser operations, we decided it was worth a try."
Founded in 1992, TruCut Fabricators originally supplied pre-cut steel components to its sister company Sterling Blower, a manufacturer of pneumatic material handling systems and industrial fans. It expanded these capabilities in order to provide outsourcing fabricating to a wide range of OEM customers. In 1999, it moved into new, 60,000 square foot facilities in Forest, Virginia where it employs 60 full time workers. The company now offers full service metal fabrication including CNC laser cutting, CNC punching, CNC press brake forming, MIG, TIG, Spot and Stud welding, vibratory tumbling, straight graining, and rolling.
TruCut challenges its workers to find new and better ways to improve its quality and productivity as part of a continuous improvement program, and periodically examines each of its processes. On its Trumpf laser, TruCut was using a low absorption lens following consistent maintenance procedures recommended by the lens and laser system manufacturer to achieve highest part quality while maximizing the life of the lens. The maintenance steps included a careful inspection of the lens and cleaning of the surface every 8 to 10 hours of operation with acetone and reagent grade polishing compound. Detailed records of these steps were kept for 4 weeks, first with the lens TruCut originally used, then for 4 additional weeks with the new Mate PEAK laser lens.
PEAK Lens Has 22 Percent Greater Life In 4 Week Test --
Matches Up Extremely Well With Trumpf Laser Performance
"The first thing we observed with the PEAK lens," Jones reported, "was that it was more resistant to build up on the surface. We operated our other lens about 540 hours before buildup and lens burn compromised the laser beam and required replacement. With the Mate PEAK lens, when we got to the 540 hour level, there were no signs of lens wear or lens burn. So we continued to operate the laser with it. At the end of the four weeks, we reached 656 hours with the PEAK lens. That was a 22 percent improvement over the old lens. What's significant is that we continue to operate that PEAK lens far beyond the tested 656 hours without any indication of lens degradation or failure."
The Mate PEAK lens design matches up ideally with the performance requirements of the Trumpf laser. The system is the Model 3000 CO2 laser, a 200-3000 watt system with 0.6 beam quality K (M2)4, a pulse frequency of 100Hz-100kHz and a pulse width of 10 us-cw. It has a square, folded resonator design that gives the laser compact size with maximum internal beam length. It has powerful turbo blowers that generate minimal noise and vibrations. Overall, it is very good laser system for TruCut's general purpose needs meeting their highest standards for quality and reliability.
Similarly, Mate's PEAK lenses are best suited to general purpose work where high output and quality is the name of the game. These lenses, for example, offer peak performance in a broad range of CO2 cutting applications requiring as much as 6000 watts and as little as 1000 watts. The lenses are designed with superior substrate adhesion, which assures uniform and consistent lens coating so there is no loss of beam quality or accuracy at all power ranges. This proprietary lens design creates an impermeable moisture resistant surface that guarantees maximum lens stability, consistency, reliability and performance. Absorption is rated at 30-40% below standard lenses (=0.15%) for longer lens life. Also, HeNe beam compatibility allows for safe set up and operation.
Laser System Quality And Speed Improved With Mate PEAK Lens
"The 3/8 and 1/4 inch hot rolled steel parts using the PEAK lens had better appearing edges than with the previous lens," reported Jones. But the biggest improvement in higher quality edges occurred on the 7 gauge hot rolled steel parts."
As for cutting speed, the improvements Jones reported were equally dramatic:
- 7 gauge hot rolled steel improved from 100 inch/min to 115 inch/min.
- 1/4 inch hot rolled steel improved from 52 inch/min to 54 inch/min. (using N2).
- 1/4 inch hot rolled steel improved from 85 inch/min to 90 inch/min. (using O2).
- 5/16 inch hot rolled steel improved from 70 inch/min to 81 inch/min.
According to Jones, "The PEAK lens improved virtually all of the hot rolled steel laser processing operations from thick to thin material. We eliminated less than desirable edges on 7 gauge and 1/4 inch thick parts. Holes overall were more consistent over the large (80 x 160 inch) cutting area of the laser system table. We've been very satisfied with Mate's PEAK lens."
For more information on TruCut Fabricators, call 1-434-316-5310 or write to 135 Vista Centre Drive, Forest, Virginia 24551-3964. Fax: 434-316-5910 Website: www.trucutfabricators.com
For more information on Trumpf Laser Systems, call 1-860-255-6000 or write to TRUMPF Inc., Farmington Industrial Park, Farmington, CT 06032. Fax: 1-860-678-1704. Website: www.us.trumpf.com
For more information on Mate's PEAK laser lenses, call for FREE brochure in USA and Canada, 1-800-328-4492. Outside USA and Canada, call 1-763-421-0230.
Or write to MATE LASER TECHNOLOGIES, 1295 Lund Boulevard, Anoka, Minnesota 55303. USA and Canada, Fax 1-800-541-0285. Outside USA and Canada, Fax 1-763-421-0285.
Website: www.mate.com Email: marketing@mate.com
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