12 Experiments in Complex Surface Machining

The results of 12 different experiments were compared to see how the two lasers performed in machining complex curved surfaces. The results were measured in terms of cutting precision, processing efficiency, and material adaptability.The report compares the two technologies, providing users with a reference for choosing which to use, and helping to solve problems in the process of precision machining.

Why compare UV lasers and fiber lasers?

In the field of precision machining, complex curved surfaces (such as those found in medical equipment and optical elements) require extremely high levels of craftsmanship.In this article, we will compare the two main technologies, ultraviolet lasers and fiber lasers, to help you decide which is the best option for you.

Experimental design: Simulating real processing conditions.

Materials and test parameters.

We have selected three common materials--stainless steel, ceramic, and polyimide film--to cover the high-frequency requirements of industrial processing.For every experiment, the variables are controlled: the power is set at 30W, and the focused spot diameter is adjusted to within a ± 5-μm tolerance. The experiments are conducted as closely as possible to actual production conditions.

Key indicators and methods of measurement.

The surface roughness is measured by a three-dimensional contour meter, the quality of the cut edge is observed with an electron microscope, and the heat affected zone is analyzed by infrared imaging.Special note: All data are the average of three measurements to avoid chance errors.

The results show which of the two is the better at fine processing.

Precision and thermal effects.

When cutting 0.1 mm holes, the UV laser produces 60 % less burr than the fiber laser.The heat-affected zone of a UV laser is only 3μm, while the heat-affected zone of a fiber laser is 12μm.However, the fiber laser is faster at cutting 5 mm thick stainless steel, with a 40 % reduction in single-pass penetration time.

Complex curved surface adaptability.

When the same group of 3D molds were used to test curved surface marking, the UV laser had a higher tolerance for focal depth.When the curvature of the surface exceeds 15 degrees, the clarity of the markings produced by fiber lasers decreases noticeably, but UV lasers can still maintain more than 90 % contrast.

Cost and maintenance: How to choose for the long run.

Equipment and material costs.

The price of a fiber laser is about 30 % lower than that of a UV laser of the same power, but the UV laser has a longer service life.Taking an eight-hour workday as the standard, the replacement cycle for UV laser modules is approximately 1.5 times that of fiber.

A test of maintenance difficulty.

Interviews with maintenance personnel at six factories found that the alignment of the optical path in a fiber laser is simpler, and a new employee can be trained in two hours to operate one.The UV laser requires regular cleaning of the lens, which means that the workshop has to be even cleaner.

Suggestions for practical application.

If you mainly process thin-walled precision parts (such as camera mounts for mobile phones), then the comprehensive performance of UV lasers is better.However, when it comes to mass production of thicker parts (such as automotive gears), the cost / performance advantages of fiber lasers are even more apparent.Of course, the final decision should take into account the budget and the plan for upgrading the process. Remember to leave a 20 % power reserve to meet future needs.