Specific to incorporating laser cutting into stamping operations, MetalForming enlisted the expertise of Danyel Benoit, international business development consultant for HSG Tech Inc. Its HSG Laser division, with North American headquarters in Addison, IL, supplies fiber laser cutting equipment for sheet and tube, as well as welding and automation equipment, to metal formers and fabricators worldwide.
For stampers exploring the addition of laser cutting technology, Benoit recommends that they do their homework. This includes identifying potential applications based on the advantages described above, and then selecting the right type of machine to match potential applications. Such machines should provide simplified integration into workflows, he says, backed by training and expertise provided by suppliers to ease operation and potential for success.
Suppliers of laser cutting machines offer various capabilities and options to best fit certain applications, and provide machines that offer the best bang for the buck for stampers looking to incorporate the technology. For its part, HSG recently has debuted the Laser Cell 3015G, a five-axis laser cutting solution that features an advanced cutting head, high-performance motion control, enhanced safety features, and high productivity and efficiency, according to Benoit. Such an arrangement provides accessible 3D laser cutting technology for stampers while negating the need for hard tooling, and also offers high cutting speeds and automation that help increase productivity while reducing labor costs. And, a variety of layout configurations ease incorporation on shop floors and within production cells.
Armed with the right solution, stampers can incorporate laser cutting and employ it effectively, as the process proves particularly well-suited for applications that require intricate parts, rapid prototyping or specialized materials. Ideal applications forwarded by Benoit include automotive and aerospace assemblies due to production of tight-tolerance, complex components; medical, which often demands small, precise parts; electronics for production of intricate circuit boards and enclosures; and architecture, often calling for custom decorative panels and facades.
Laser Cutting vs. Stamping
Benoit provices a tale of the tape, comparing laser cutting to stamping, pointing out advantages of each. Of course, these are generalities, and specific applications may tip the balance either way.
Volume and cost/part: Laser cutting often beats stamping for low- to medium-volume work, offering a lower cost/part due to no hard-tooling cost, while stamping provides a lower cost/part for high-volume jobs.
Complexity: Laser cutting in general gets the call for high-complexity operations, while stamping proves better for low- to medium-complexity. For example, the flexibility of laser cutting machines, especially with the support of 3D cutting heads, allow cutting of complete part contours within a single station—a productivity-boosting solution, according to Benoit.
|
Save the dates, May 21-22, for the Fabrication Strategy Summit in Northbrook, IL, where top industry professionals will offer insight on incorporation of fabricating technology into stamping operations, among other hot-button topics. This two-day interactive event, from MetalForming and the Precision Metalforming Association, features keynote speakers and targeted, facilitated roundtables covering design for manufacture; scalable process integration via software and automation; smart manufacturing/Industry 4.0; the transition from high-volume low-mix production to low-volume (and prototype) high-mix work; and more. The format will allow for meaningful dialogue and networking opportunities, fostering collaboration and knowledge-sharing, and encouraging attendees to engage with the subject matter. Suggested audience: operators of laser, plasma or waterjet cutting equipment; bending or folding machines; punching machines; welding equipment; automation equipment; and more. For details and to register, visit metalformingmagazine.com/event/?/fabrication-strategy-summit. |
Lead time and tooling: Laser cutting has a shorter lead time, due to quick programmed setup and no need for hard tooling.
Flexibility: Laser cutting offers greater flexibility for design modifications and customization. A hard-tooled stamping operation is less flexible.
Noise: Laser cutting’s contactless cutting process eliminates the noise and vibration, common byproducts of stamping.
Material waste: Laser cutting generates minimal material waste due to its precision, while stamping can produce more waste, especially during setup and with less-efficient nesting layouts.
Taking all of the above into consideration, the most effective solution involves not viewing laser cutting and stamping as an either/or decision, but finding ways to let the processes complement each other.
For example, metal formers can use laser cutting before or after stamping. Laser blanking eliminates the need for blanking dies—simply program a CNC laser unit to cut desired shapes. Blanks can be delivered quickly, and in a surprisingly high volume. And, rather than invest in complicated hard tooling, a stamper can employ a laser to trim parts or add hole features after forming in a press. Partnering the processes doesn’t end there.
“Offering laser-cut parts while developing stamping tooling is a smart strategy, due to long lead times often associated with creating hard tooling,” Benoit explains. “And, adding laser cutting expands capabilities beyond traditional stamping, opening a new world of possibilities.”
These possibilities include taking on new lower-volume and prototyping work, and positioning stamping operations as one-stop shops that can meet a variety of customer needs. MF
View Glossary of Metalforming Terms
See also: HSG Laser Co., Ltd
Technologies: Cutting
