What measures can reduce distortion in laser-cutting processes?

What Measures Can Reduce Distortion in Laser-Cutting Processes?

Optimize Cutting Parameters

Distortion in laser cutting is often caused by excessive heat input. To control this:

• Use appropriate power settings for material type and thickness (e.g., ≤1.5 kW for 1–2 mm stainless steel).

• Adjust cutting speed to balance penetration and heat accumulation—faster speeds minimize heat build-up and warping.

• Select the correct assist gas: Nitrogen or air reduces oxidation and heat transfer, ideal for thin metals.

Minimize Heat-Affected Zone (HAZ)

A narrow HAZ reduces thermal expansion and residual stress:

• Use pulsed lasers or high-frequency modulation to control energy delivery.

• Employ fiber lasers with shorter wavelengths and higher energy density for focused, low-heat impact cuts, especially on thin sheets or precision components.

Strategic Cutting Path Planning

Toolpath design affects heat distribution:

• Alternate cut locations across the sheet to prevent local heat accumulation.

• Segment long cuts into shorter passes, allowing intermittent cooling.

• Avoid small internal features first—cut larger contours first to stabilize the material.

Material Fixturing and Support

Proper fixturing prevents thermal movement during cutting:

• Use clamping systems or magnetic tables to hold thin or flexible sheets flat.

• Implement slat beds or honeycomb supports that minimize thermal contact and reflection-induced distortion.

Preheat and Stress Relief

For thick or highly stressed materials (e.g., >8 mm mild steel):

• Preheat the material to 100–150 °C to reduce thermal gradients and warping.

• Apply post-cut stress-relief annealing in critical aerospace or energy system components where dimensional stability is essential.

Simulation and Quality Control

• Use laser path simulation software to detect potential stress zones before cutting.

• Monitor sheet temperature with infrared sensors and implement cooling pauses if needed for long or intricate jobs.

Manufacturing Services for Precision, Distortion-Free Laser Cutting

Neway delivers laser cutting services with ±0.01 mm accuracy, distortion control strategies, and CNC integration. With 20+ years of experience, we provide global clients in the automotive, medical, and telecommunication sectors with stable, high-quality parts.