The Tools of Artificial Intelligence (AI)

 The manufacturing industry is being hit with a massive labor shortage. As new demand surges for skilled labor, the technology of manufacturing in most areas have been lacking. For this reason, Mitsubishi released their all-new GX-F Advanced fiber laser, with AI capabilities to allow for non-stop processing.

Artificial Intelligence is the future of manufacturing.

How does AI work in manufacturing?

Depending on the tasks desired to complete using the technology, AI is used to teach and then test the machines to learn optimization patterns. In the case of Mitsubishi’s GX-F Advanced fiber laser system, artificial intelligence is used to optimize gas usage. As AI implies, the program is intelligently programmed to teach and deploy the best strategy to cutting metal. The result – a machine that constantly cuts better and better. It is as if a production operator never stopped learning while on the job – and how often does this happen?

Your company’s next best employee will be automated. AI is used to optimize machines on its cutting accuracy and effectiveness while minimizing the resources used and problems that may occur. In other words, it is everything that a typical operator may continue to do while on the job – but without the operator. This saves costs and the risks associated with traditional low-skilled production operators in a manufacturing facility.

AI can be used in a variety of ways for cost savings. Anywhere there is a metric to optimize for, AI can be put to use. For example, if you need to maximize power consumption, machines can take consistent readings and figure out what processes drain the most amount of energy, and then shift processes to minimize its usage. Similarly, when the machine knows what the costs are associated with using certain resources and the like, then AI can figure out the best ways to save costs and alter how much time is spent on certain processes to produce better results.

How does the GX-F Advanced fiber laser work with AI?

We won’t spend time talking about this machine’s specifics, but you can find them here. To use artificial intelligence, the general conditions in the machine are adjusted and corrected in real-time. What this means is that while the fiber laser machine runs and learns more, it will begin to optimize itself. Its cutting system is intelligent, meaning that it constantly adjusts to what is required for it. The GX-F advanced also provides online job scheduling and runtime estimates. With the operations being accessible remotely, the machine operators can set up jobs even when they’re not on the production floor.

The best part of these machines is the package that these lasers include. Not only do these machines produce high-quality results, but all service and support are done through Mitsubishi themselves. In other words: Everything is done through the manufacturer. That is, everything aside from the sale itself – which is why Carlson Fabrication Solutions can help you find and select the best fiber laser for your manufacturing business. We act as your consultants, and only want our customers to purchase what is truly best for their metal manufacturing business.

Do you have any questions about Mitsubishi lasers?
Contact us at info@carlsonfab.com or at (781) 937-9599

Fiber Vs. CO2 Laser Cutting for Metal

BENEFITS OF USING A FIBER LASER VS A CO2 LASER FOR METAL CUTTING

Fiber Lasers are faster, more accurate, and can save you lots of money.

The advent of fiber laser cutting machine has been the biggest game-changer in sheet metal fabrication since the 1980s when CO2 cutting was first introduced to the metal fabrication industry. When compared to CO2 lasers, fiber laser technology has really pushed the boundaries of laser cutting into a whole new era.

How did fiber lasers change the game

Within five years of introducing fiber laser, it reached a cutting range of 4kW, a feat that took CO2 lasers about two decades to achieve. Within another five years, fiber lasers were able to reach a threshold of over 10kW, something CO2 can never do. Even some fiber lasers can do beyond 20kW, but those are useful for industries aside from sheet metal cutting. Since sheet metal processing typically deals with metal under a quarter of an inch, too many kilowatts can just be overkill for cost and energy consumption. The ideal machines for sheet metal processing typically fall within 4-8kW, and the speed/accuracy are the most important factors to consider.

The fiber laser beam uses a laser generator to produce a laser beam with high power density. The laser beam hits the surface of the material through the optical path system until the material gets to its boiling or melting point. Just like the CO2 laser, there is a high-pressure gas that blows the material melt away.

FIBER VS CO2 LASER CUTTING

Aside from the impact it has had on the industry, fiber laser machining has plenty of advantages over the CO2 laser:

1. Fiber lasers require little or no maintenance and part replacement as compared to CO2 lasers that require periodic and yearly maintenance and part replacement. This affects the overhead cost of the company.

2. Fiber lasers provide a reduction in power loss and higher energy efficiency because it adopts a laser optic cable as against mirrors and channels being used by CO2 laser cutting machines. This also means that a Fiber laser will reduce the cost of production.

3. Fiber lasers produce more focused beams on the metals. This is due to the fact that the fiber laser frequency is ten times more than that of CO2 because the former has a shorter wavelength.

4. Fiber laser machines offer superior cutting accuracy and sharp cutting edge. The cutting table makes sure the cutting process is stable.

CO2 Lasers are best for cutting deep into metal, and are best suited for thick metals.

5. The need for sheet metals in the manufacturing industry is increasingly becoming more significant. The fiber laser machine is best suited for sheet metals, as it can take care of this demand, while CO2 laser machines are best used for cutting thick plates.

6. A 2kW Fiber laser has a focused beam that possesses five times the power density at a focal point compared to a 4kW CO2 laser. The fiber laser beam will also have about three times more absorption characteristic due to its shorter wavelength.

7. The high absorption and power density characteristics of fiber lasers, created by the focused beam, makes it cutting speed to be five times faster when operating on materials that are less than one-fourth of an inch thick.

8. Fiber laser machines can run on a dual interchangeable platform, such that the workpiece and the finished sheet can be loaded or unloaded automatically. This will reduce time-wasting and the stress of doing a repetitive job.

Want to learn more about fiber and co2 lasers?

FIBER LASER MACHINES | CO2 LASER MACHINES

Carlson is NEW ENGLAND’S OFFICIAL DEALER OF MITSUBISHI’S MC MACHINERY

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 For more information, also see:

• FIBER LASER CUTTING

• CO2 LASER CUTTING

• MITSUBISHI LASERS & PRESS BRAKES

The difference between 5-axis and 3-axis machining

Mitsubishi’s 5-Axis CO2 Laser: VZ20-Series

In most production processes, machining is the largest value-add. Machining involves the removal of excess raw materials in other to produce high-quality parts by water jet cutting or by laser cutting.

In the years past, people carry out this machining operation by using 3-axis machining tools, but in recent years due to technological advancement and increased use of digitally controlled (CNC) people are now subscribing to the more modernized 5-axis machine.

In this article, we will look at what each of the machines entails and the significant difference between the 3-axis and the 5-axis machine.

3 Axis Machine vs 5 Axis CNC Machining

A 5-axis machine keeps the same 3 (X, Y, Z) axis’s but instead adds both the “A” and “B” axis (shown above).

1. Conventionally, materials were fed and worked on three axes (X, Y and Z).

   Traditional laser cutting machines removed material in three fundamental directions, similar to the Cartesian coordinates. Being the mode of operation of the 3-axis machine, 3-axis movement was and still is suitable for parts that have little depth. However, the 3-axis technique cannot handle deeper parts and ones that have narrow cavities because it can be a tasking process to complete on a 3-axis machine.

   On the other hand, 5-axis machines, as its name implies, move in five directions which include three linear X, Y and Z axes with an additional two axes (A and B) around which the tool rotates. This means that every material feed into the machine can be approached in all five directions.  5-axis machining is recommended for deeper parts and more hardened materials, and can guarantee an extremely accurate result. This precision can be attributed to its shorter machining tools, faster tool speed and a reduced vibration tool.
   
   
   

2. A 3-axis machine produces a cusp when a curved material is feed into it.

   This occurs because the machine has a ball-nose endmill (corner radius). A cusp is formed due to a cross-feed between the material and the machine. In a 5-axis machine, the possibility of cusp formation is reduced, because the two extra rotational axes are used to tilt the tool, thereby reducing the chances of cusp formation.

3. A 5–axis machine delivers quality surface finishes with impressive speed.

   This is due in part to the fact that the machinery adopts flat and radiused-corner endmills. The additional axes are used to adjust the rotation and tilt about the surface normal on the workpiece. With greater axes, the machine can become more versatile, and will save the machinist time from having to make continuous adjustments. However, this all comes at a cost, as the greater number of axes will make programming more tricky, so it will require more expertise in operators who are hired for the job, which may bring up costs.

4. In recent years, more innovations in both hardware and software have been developed for complete computer-based control of the tools used by 5–axis machines.

   With the aid of digital controls, there are more efficient ways to handle numerous materials and curved surfaces, thereby enabling production with a high degree of accuracy. Also, with the help of computer-aided manufacturing (CAM), the machining process can be fully or partially automated. 5-axis laser cutting can be seen at the forefront of these innovations.

Other advantages of the 5-axis machining technology include:

With faster machines come a faster need for more advanced CNC controls and automation software.

• faster machining speed

• ability to manufacture Larger-sized parts

• higher yields

• lesser downtime for switching between tooling.

Even though 5 axis machine takes longer preparation and completion/turnaround time, it becomes clear that from the above comparisons that every manufacturer should move with technology by embracing the 5-axis machine, to increase their efficiency and overall level of production.

If interested in learning more about 5-axis machines (particularly laser cutting ones), please see our 5-Axis Co2 Laser Cutting Machines by Mitsubishi for more information.

Also See:

• 5-AXIS CO2 LASER CUTTING

• FIBER LASER CUTTING