How to use laser cutting to reduce the scrap rate and improve the quality of the cut in the raw material cutting stage of stainless steel guardrail processing?
Publish Time: 2024-12-17
In the initial stage of stainless steel guardrail processing, raw material cutting is extremely critical. It is not only related to cost control, but also closely related to the assembly accuracy and overall quality of subsequent products. The application of laser cutting technology brings hope to solve the problem of high scrap rate and poor cut quality.
Accurate layout is the core strategy of reducing waste by laser cutting. With the help of professional CAD/CAM software, technicians can simulate the layout of stainless steel plates according to the size specifications and order quantity of the guardrail. For example, when continuously producing a batch of balcony guardrails of standard height, the software carefully plans the layout of each plate, and nests the graphics of different components compactly, just like playing a precise jigsaw puzzle game, maximizing the use of the plate area, and greatly reducing the waste of corners. For example, in the past, the proportion of single cutting waste under extensive layout reached 20%, which can be controlled within 5% after optimization, effectively saving raw material costs.
Fine adjustment of laser cutting equipment parameters directly affects the cut quality. The three elements of power, speed and frequency check and balance each other. Too high power can easily cause excessive melting of the plate, rough cuts, or even ablation deformation; too low power will result in incomplete cutting. According to the characteristics of stainless steel, after multiple tests, when cutting 3 mm thick plates, the laser power is set to 1500-1800 watts, the cutting speed is adjusted to 30-40 mm/s, and the pulse frequency is set to 300-400 Hz, which can make the cut smooth and almost mirror-like, without burrs or slag to interfere with subsequent processing, ensuring that the guardrail is assembled tightly.
Real-time monitoring and feedback correction system escorts cutting. Advanced laser cutting machines are equipped with high-resolution cameras and sensors to keep a close eye on the cutting process. Once the cutting path deviation and energy fluctuations cause abnormal cutting, feedback is immediately sent to the control system to automatically fine-tune the laser parameters or suspend error correction to avoid scrapping the entire plate. For example, when cutting guardrail parts with complex carved patterns, minor deviations can be corrected in time to ensure that the patterns are exquisite and complete, and the scrap rate has dropped from 8% of the conventional process to less than 2%, significantly improving the utilization rate of raw materials and the output of good products.
The selection of auxiliary gas and injection optimization for guardrail processing should not be underestimated. Oxygen combustion improves cutting efficiency, but oxidation reactions are easy to leave traces; nitrogen is highly inert and can inhibit oxidation, making the cut pure. According to the composition and process requirements of stainless steel, nitrogen is selected as the auxiliary gas, and is precisely sprayed in a laminar flow through a special nozzle to blow away the slag and cool the cut, helping to create cut parts with neat edges and bright colors, reducing the burden on subsequent welding and grinding processes, accelerating the high-quality output of stainless steel guardrail products, and consolidating product competitiveness from the source.
