• English
  • 中文
  • Français
  • Deutsch
  • Español
  • Português
  • 日本語
  • 한국어
  • Nederlands
  • Türkçe
  • Bahasa Indonesia
  • ไทย

Sheet Metal Laser Cutting: Kerf, Gas and the Tolerances We Put in Writing钣金激光切割:切缝、辅助气体,以及我们敢写进合同的公差

A German audio equipment maker sent us photographs before they sent us a drawing. Their 2 mm 304 stainless front panel, 420 × 260 mm, was arriving with the outline right and the hole pattern wrong: six M4 clearance holes that had to drop over studs on a machined subplate, drifting by up to 0.35 mm at the corners of the pattern, brown oxide edges that had to be scrubbed before powder coating, and roughly 0.6 mm of bow across the long axis that no shim at assembly could absorb.

The supplier was not careless. They were cutting with oxygen on a CO2 machine, running one nesting layout across the panel family, and applying a single kerf offset to every hole. Each of those is ordinary shop practice, and each one costs money at assembly.

We changed four things: nitrogen instead of oxygen, a separate kerf offset class for holes instead of a global one, a re-nest that put the vent pattern on a common cut line, and a short CNC pass on the six holes that actually controlled the fit. The hole pattern went from ±0.20 mm to ±0.05 mm, the scrub step disappeared, and the panel came off the brake flat. Gas cost went up; finishing, scrap and assembly labor went down by more.

*(Composite example; details changed.)*

That job is the reason this guide exists. Our sheet metal fabrication guide compares laser against punch and waterjet at the process level, which is where to start if you are still choosing a method. This page stays inside the laser: what the beam does to the metal, what the assist gas does to the edge, where kerf and taper eat your tolerances, and how each decision lands on the unit price. It is for the engineer who already knows they need sheet metal laser cutting and wants to see what the supplier is deciding on their behalf.

What a fiber laser actually does to the metal

A laser does not cut. It melts a narrow track and a coaxial gas jet blows the melt out of the bottom of the sheet. Everything about edge quality, tolerance and cost follows from three quantities: the wavelength of the light, the power density at the focused spot, and how reliably the molten material leaves the kerf instead of refreezing on the underside.

Wavelength and absorption: why fiber won

Two technologies dominate metal cutting, and they differ by a factor of ten in wavelength.

AttributeFiber laserCO2 laser
Wavelength1.06 to 1.08 µm, typically 1070 nm10.6 µm
Absorption on cold steelMaterially higher, and rises steeply once a melt pool formsLow until the surface melts, then unstable on reflective alloys
Focused spotSmall, high power densityLarger at equal optics, lower density
Speed on 1 to 3 mm sheetTwo to five times faster at equal rated powerSlower
Thick plateCompetitive to 20 mm and beyond on modern high power unitsHistorically the thicker-plate choice
Wall-plug efficiencyRoughly 25 to 35 percentRoughly 5 to 10 percent
Reflective metalsWorkable with the right pierce strategyPoor, with real back-reflection risk
Non-metalsPoor, the beam passes through many plasticsStrong, absorbs well in organics

Absorption is the whole argument. At 1 µm, cold steel takes in several times more of the incident energy than at 10.6 µm, and once a melt pool exists the absorptivity climbs steeply. That is why a fiber source pierces reliably on stainless and aluminum where an older CO2 source hesitates or trips on reflected light, and why a smaller focused spot compounds the advantage. Add the efficiency gap and you get the outcome every buyer has noticed: fiber laser cutting is now the default quote for stainless and aluminum under roughly 8 mm, and CO2 is a legacy process kept alive by installed base and non-metals.

CO2 survives on clear plastics, on very thick plate in older shops, and on legacy part families whose kerf width and edge color belong to the original validation. We tell you on the quote when a part would move from one source to the other, because a different source on the same DXF is not the same part.

Kerf width and kerf compensation

The kerf is the material the beam removes. It is not a line, it is a slot, running roughly 0.1 to 0.4 mm on sheet metal depending on material, thickness, gas and focus, widening with thickness. Anything you dimension on a laser cut sheet metal part is measured after that slot has gone, so the programming offset decides your finished size.

Material and thicknessAssist gasTypical kerfComment
1.0 mm stainless 304Nitrogen0.10 to 0.15 mmClean, near parallel walls
2.0 mm stainless 304Nitrogen0.15 to 0.20 mmOur everyday production case
3.0 mm cold rolled steelOxygen0.20 to 0.25 mmWider because the reaction adds heat
6.0 mm cold rolled steelOxygen0.25 to 0.30 mmTaper starts to show on the wall
2.0 mm aluminum 5052Nitrogen0.20 to 0.25 mmReflectivity and conductivity widen the track
8.0 mm cold rolled steelOxygen0.30 to 0.40 mmHole sizes now measurably top versus bottom

Compensating the kerf, and what it does to hole sizes

The CAM system offsets the cut path by half the kerf: outward on an external contour so the part reaches nominal, inward on a hole so the hole opens to nominal. The failure mode we see on incoming programs is one global offset applied to every feature on the sheet.

Kerf is not constant across a nest. Holes are cut slower and with more dwell than long profiles, corners decelerate and dump heat, and pierce conditions differ from a through-cut, so holes cut slightly wide relative to the profile offset. One global offset leaves external dimensions near nominal and holes undersized. On the panel above, the holes ran 0.10 to 0.15 mm small, consistently.

We run separate offset classes: one for the external profile, one per hole diameter band, one for slots. We cut a coupon from the actual sheet lot, measure it, adjust, then release the nest. If you are evaluating a supplier, ask what offset they applied and whether they verified it on a coupon. It takes ninety seconds to ask, and it is the difference between a hole pattern that assembles and one that nearly does.

Assist gas: the decision that costs real money

Assist gas does two jobs when you are laser cutting sheet metal: it blows melt out of the kerf, and it either protects the cut face from oxygen or deliberately adds oxygen to the reaction. That second job is a fork in the road, and it is the most under-discussed line on a laser quote.

Nitrogen versus oxygen: what you are actually buying

Nitrogen is inert. The cut face comes out bright and oxide free, weldable without grinding, and ready for powder coating after nothing more than a deburr. It is slower than oxygen on carbon steel and it is consumed at high pressure, so it costs more per part.

Oxygen is not just a purge, it is a reactant. On carbon steel the iron burns, and that reaction supplies much of the cutting energy, so feed rate rises and the gas is cheaper. The price is a magnetite layer on the cut face, which has to come off before welding, because it causes porosity and lack of fusion, and before powder coating, because it undermines adhesion and telegraphs as a dark line.

On stainless the decision is not cosmetic. Chromium at the cut face combines with oxygen, the edge loses what makes it stainless, and an oxygen-cut edge will rust bloom in humidity even under a powder coat, unless abraded back and passivated. We do not cut stainless with oxygen for anything visible, washed, or coastal. Aluminum is different: the oxide is hard and thin, nitrogen is standard, and the argument there is about dross.

Assist gasRelative gas costSpeed, 3 mm carbon steelCut facePrep before weldingPrep before coatingBest for
NitrogenHighestBaselineBright, oxide freeDeburr onlyDeburr onlyStainless, aluminum, weld prep, cosmetic parts
OxygenLowestUp to 30 to 50 percent fasterDark magnetite layerGrind or blastGrind or blastCarbon steel, hidden edges, structural parts
AirNear zero, compressor onlyClose to oxygen on thin sheetLight straw to grey oxideGrindGrind or blastThin carbon steel that gets blasted anyway

Air cutting, and when it is fine

Air cutting runs clean, dry compressed air through the same nozzle. Gas cost essentially disappears and speeds on thin carbon steel are competitive with oxygen, so it is a legitimate choice for 1 to 3 mm carbon steel that will be blasted and coated regardless. It is wrong for stainless, because oxygen and nitrogen at temperature damage the corrosion resistance you paid for, and wrong for weld preparation. It also depends entirely on air quality: oil or water carryover from a shop compressor lands on the cut face and then under your coating. Ask about filtration and dryness before you accept it.

The way we frame the trade: the nitrogen surcharge on a panel that size is measured in cents, while a manual scrub before coating is measured in minutes of labor. Minutes beat cents, which is why our default quote on stainless and aluminum carries nitrogen with no secondary edge prep.

Heat-affected zone, dross and edge taper

How much HAZ matters, and when it does not

The heat-affected zone on a laser cut edge is narrow, tens of micrometers to a couple of tenths of a millimeter on thin sheet, and far smaller than plasma or flame produces. For most parts it is irrelevant. It stops being irrelevant in four situations.

Stainless sensitization is the first: the steel around the cut loses local chromium, and the symptom is tea staining along the edges months later. Aluminum is the second. 6061-T6 is artificially aged, and the band next to the cut sees temperatures that overage it, so local yield strength drops. That matters when a load path runs near a cut edge, and it shows as a halo after anodizing, since the softened band takes dye differently. Our anodizing guide covers why 5052 hides this and 6061 does not. Third is forming: a cut edge on the outside of a tight bend can crack. Fourth is coated stock, where zinc vaporization at a galvanized edge causes weld porosity.

For everything else, a bracket in a dry enclosure, a mounting plate, an internal chassis, HAZ is a specification worry rather than a part failure.

Dross, taper and edge squareness

Dross is melt that refroze on the underside instead of leaving the kerf. Soft dross wipes off. Hard dross needs grinding, and it is a symptom worth chasing: low gas pressure, a worn nozzle, a dirty lens, focus in the wrong place relative to the sheet, or a feed rate off the sweet spot. If every part in a batch has hard dross on the same edge, the setup is wrong, not the material.

Taper is what buyers never budget for. The kerf is not a parallel slot: it is wider at the top than the bottom, by roughly 0.02 to 0.10 mm on thin sheet and more as thickness grows, so the diameter on the top face is not the diameter underneath. ISO 9013 grades this separately, as perpendicularity or angularity *u*, with edge roughness graded as *Rz5*, and the full grading sits in our sheet metal tolerance standards guide. For your drawing: if a hole diameter is functional, say which face it is measured on.

The drag lines on the cut face are the third edge characteristic, and what people mean by laser edge roughness. We cover measurement separately in the surface roughness guide, but for quoting: a nitrogen cut on 2 mm stainless is a bright face needing no further work, and an oxygen cut on 6 mm steel is a striated, oxide-covered face that always does.

Feature limits: holes, slots, webs and corners

Minimum hole diameter scales with thickness

The rule of thumb the whole industry works to is that a round hole should be at least 1.0 × material thickness in diameter, and that 1.5 × thickness is where quality and cycle time both become comfortable. Below 1 × T the melt cannot clear cleanly, dross sticks inside the hole, and roundness suffers.

Material thicknessMinimum hole ØRecommended hole ØWhat happens below the minimum
1.0 mm1.0 mm1.5 mmDross inside the hole, ragged exit
1.5 mm1.5 mm2.5 mmSlow pierce, heat build-up
2.0 mm2.0 mm3.0 mmRoundness drifts, exit burr grows
3.0 mm3.0 mm4.5 mmConsistent dross, taper visible
4.0 mm4.0 mm6.0 mmPiercing dominates cycle time
6.0 mm6.0 mm9.0 mmConsider drilling instead

When a hole is smaller than the thickness, do not force the beam: drill it, punch it, or move it to a post-cut operation. A 2 mm hole in 3 mm stainless is a drilling job, and treating it as one usually removes cost rather than adding it. Deciding which features belong to the laser and which belong to a second operation is the core of a proper DFM analysis before quoting, and it is free when you send us the model.

Slots, webs and sharp corners

Slots want a width of at least 1.0 × T and are happier at 1.2 to 1.5 × T. Length matters too, because a slot longer than about eight times its width starts to close up from heat. If you need a long ventilation slot, break it into two shorter slots with a bridge.

Webs between adjacent cutouts are where hole patterns quietly go wrong. Keep at least 1.0 × T between two features, and 2.0 × T if either is positional, because thin webs warp under the beam and drag the neighboring hole off location. Keep holes at least 1.0 × T from the part edge, 2.0 × T preferred.

Sharp internal corners are the last trap. A laser can notionally produce a near-zero radius, but the axis decelerates into the corner and the dwell rounds it. Put a radius of at least 0.5 × T on internal corners, and 1.0 × T where the corner is load-bearing or cosmetic. Watch small islands too: a fragment of skeleton surrounded by cut lines will heat, lift and collide with the head.

Fiber laser cutting a stainless sheet metal panel
Fiber laser cutting a stainless panel: the coaxial gas jet clears the melt downward, and what does not leave becomes dross on the underside.光纤激光切割不锈钢面板:同轴气流向下吹除熔体,未吹净的部分在背面形成挂渣。

How thick can we cut: carbon steel, stainless, aluminum, brass, copper

Steel, stainless and aluminum

Capability is not a single number per material. It is a band where the edge is still good, then a band where the part is cuttable but slow and the edge quality is a compromise.

MaterialComfortable production bandCuttable but slowerPreferred gasNotes
Cold rolled and hot rolled mild steel0.5 to 12 mm12 to 25 mmOxygen or nitrogenOxygen is fast and cheap; nitrogen when the edge welds or coats
Stainless 304 and 3160.5 to 8 mm8 to 12 mmNitrogenOxygen costs you corrosion resistance at the edge
Aluminum 5052 and 60610.5 to 6 mm6 to 8 mmNitrogenReflective, conductive, dross-prone as thickness grows
Galvanized steel0.5 to 6 mm6 to 10 mmNitrogenZinc vapor needs extraction and complicates welding
Brass C260 and C3600.5 to 4 mm4 to 6 mmNitrogenZinc fume; leaded grades raise handling questions
Copper C1100.5 to 2 mm with the right setupAbove that, specialistNitrogenSee the reflectivity note below

Brass and copper: the reflectivity problem

Copper separates shops that own a laser from shops that can cut copper. At room temperature copper absorbs only a small fraction of 1 µm light and reflects nearly all of it, so the beam bounces until a melt pool forms. The transition is abrupt, the reflected energy travels back up the path that delivered it, and a machine without back-reflection protection can be damaged in a fraction of a second. That is why many suppliers quietly decline copper, and why a busbar RFQ deserves a conversation rather than a checkbox.

Brass is more forgiving, because the zinc changes absorption and thermal behavior, and free-cutting grades cut cleanly up to a few millimeters, at the cost of zinc fume and, on leaded grades, handling rules some customers will not accept. Pure copper above roughly 2 mm is better produced by waterjet or machining, and we will say that on the quote rather than sell you a marginal laser job.

Two related cases catch people out. Polished or mirror-finish stainless reflects far more than mill finish, so the cosmetic face you specified changes the cutting parameters, and PVC-coated sheet cuts well with the film on but burns back at the cut edge and adds its own fume. If a supplier never asks about finish or coating, they are quoting the material in the drawing, not the material on the pallet.

Laser cutting tolerances we will put in writing

Here is the band we commit to on cut features, in the flat, on a properly nested and clamped sheet, measured at room temperature.

Material thicknessProfile toleranceHole diameter toleranceHole-to-hole within one nest
0.5 to 1.0 mm±0.05 mm±0.05 mm±0.05 mm
1.0 to 2.0 mm±0.08 mm±0.05 to 0.08 mm±0.05 mm
2.0 to 3.0 mm±0.10 mm±0.08 mm±0.08 mm
3.0 to 6.0 mm±0.15 mm±0.10 mm±0.10 mm
6.0 to 10 mm±0.20 to 0.30 mm±0.15 mm±0.15 mm
Above 10 mm±0.30 mm and up±0.20 mm and upTaper dominates the result

Three caveats belong with that table. It assumes the sheet is flat and clamped, because a sheet with residual coil set moves as it is cut, and that critical parts are nested away from the sheet extremities, where thermal growth shows up first on a 1.5 × 3 m table. And it is a cutting number, not a machining number: if a feature genuinely needs ±0.01 mm, we hold that by machining after cutting. Every millimeter below this band is bought with a second operation.

Why cut tolerance and bent tolerance are different numbers

This distinction resolves most "the parts do not fit" arguments. A dimension that lives entirely in the flat inherits the table above. A dimension that crosses a bend inherits the press brake instead: springback, thickness variation, tooling wear, and the K-factor used to unfold the flat. In practice a cut profile at ±0.05 mm becomes a formed flange at roughly ±0.25 to 0.50 mm, and a K-factor error of 0.05 alone shifts a flat pattern by a few tenths per bend.

So keep functional dimensions off the bend wherever geometry allows, and where it does not, either specify the feature in the formed state and machine it after forming, or design the joint to live inside the wider band. The derivation and the springback figures by alloy are in our bend allowance guide, and the classes for what the drawing should say are in the tolerance guide.

On hole patterns, write a position tolerance rather than coordinate ±. A coordinate callout of ±0.10 in X and ±0.10 in Y produces a square acceptance zone whose corner sits 0.141 mm from true position, and that corner is where assemblies fail. The ASME Y14.5 standard is the reference we dimension to when a customer names one.

Press brake bending a laser cut blank
Press brake forming a cut blank: from this point on, every dimension that crosses the bend belongs to the brake, not to the laser.折弯机成形已切割坯料:从此刻起,跨越折弯的尺寸归折弯机管,不再归激光管。

Nesting, material utilization and where the laser stops paying

Nesting is the layout of parts on the sheet, and material utilization is usually the largest single line in the unit cost of a laser cut part. Sheet is bought by area and the skeleton is sold back as scrap at a fraction of what it cost, so a nest running at 60 percent throws away 40 percent of the material you paid for.

The lever buyers rarely pull is the outline itself. On one bracket family we reviewed, a 20 mm cosmetic flange and a decorative 10 mm corner radius were forcing the parts apart on the sheet. Relieving the flange to 12 mm and squaring one corner let two parts share a cut line and moved the nest from 61 to 69 percent: eight percentage points of utilization, or about 12 percent less material per part. That 1 mm of contour roughly covered the nitrogen surcharge, and changed nothing the assembly cared about.

Common-line cutting saves time as well as material, because one traverse separates two parts instead of two. Grain direction is the constraint that fights it: requiring bends to run perpendicular to the rolling grain prevents free rotation in the nest, which typically costs 3 to 10 points of utilization. Say it when it matters for a visible or load-bearing bend, and let it go where it does not. The wider unit-cost picture is in our CNC machining cost guide.

Where the laser stops being the cheapest route

Once a simple profile repeats more than a few thousand times a year, a stamping die pays for itself and the piece price typically drops by a factor of two to three, and the full break-even arithmetic belongs to our stamping versus laser cutting comparison. The steel that die is cut from decides how long it holds that price, which is what our stamping die material guide is about.

After the cut: deburring and the finishing sequence

Every laser cut leaves something on the edge, whether a soft dross bead of 0.02 mm or a hard burr of 0.10 mm. It is sharp, it interferes with fit-up, and powder coating will not hide it, because coating pulls back from a sharp edge.

The order we quote is: cut, deburr and break edges, form, weld, re-deburr or grind the weld zone, surface prep, coat. Deburring before forming stops the burr marking brake tooling or cracking on the outside of a bend, and oxide removal before welding is what prevents porosity, covered in more depth in the sheet metal welding guide.

Methods split by part. Vibratory finishing suits small parts and gives a uniform edge, but it can peen soft aluminum and round corners you wanted sharp. Through-feed belt and brush machines suit flat panels and give a repeatable edge break, which is what we run on parts like the panel above. Manual work is for cosmetics and is the least repeatable, while electropolishing on stainless removes the HAZ and free iron in one step.

Specify an edge break, not a feeling. "Break sharp edges 0.1 to 0.2 mm" is purchasable and measurable; "remove all burrs" is not, which is why two shops price the same deburr line differently. The options and costs are in our deburring guide, and the coating side in the finishing guide.

Surface finishing of laser cut sheet metal parts
Surface finishing after cutting: an edge that is broken and oxide free before coating is the difference between a panel that passes and one that telegraphs its cut line.切割后的表面处理:涂装前完成倒角并清除氧化层的边缘,决定了面板是合格还是把切割痕透出来。

A composite example: what the change did to the numbers

This is the 2 mm 304 stainless panel from the top of the article, with the numbers attached.

*(Composite example; details changed.)*

ItemBefore, oxygen on CO2, one offsetAfter, nitrogen on fiber, class offsets
Hole pattern position±0.20 mm, 0.35 mm worst case±0.05 mm, verified on CMM
Hole diameter spread across one sheet0.15 mm0.04 mm
Edge preparation before coatingManual scrub plus belt, about 6 minutes per partDeburr only, about 0.5 minutes per part
Flatness after cuttingRoughly 0.6 mm bowUnder 0.15 mm
Scrap and rework rate9 percent0.8 percent
Assembly fit rate1 panel in 6 needed hand reworkNo rework
Unit price index10095

Four changes produced that. Nitrogen removed the oxide, the scrub step and the heat pattern that was bowing the panel. Separate offset classes per hole diameter band removed the systematic undersize. A re-nest with a common cut line on the vent pattern moved utilization from 61 to 69 percent, which roughly covered the nitrogen surcharge. And the six holes that controlled the fit were finished on a machining center after cutting, which is where a ±0.01 mm number honestly comes from. Front panels like this are most of our audio equipment work: the outline is fine, the pattern is not. At 420 × 260 mm the panel sits inside the 1000 × 500 × 300 mm envelope of our milling centers, so that was one short program; a part needing compound angles moves to a five-axis cell, which tops out at 750 × 650 × 500 mm of travel and a Ø500 × 400 mm part.

Nothing here needed exotic equipment. It needed somebody to treat the nest, the gas and the offsets as one decision instead of three defaults.

What to send with your RFQ, and what to demand back

Eight items get you a comparable quote inside 24 hours. Two of them, quantity and critical features, decide whether laser is the right process at all.

  1. Material, temper and exact thickness, plus surface condition: 304 2B at 2.0 mm, 5052-H32 at 1.5 mm, and whether the sheet arrives with PVC film, brushed finish or mirror polish.
  2. Geometry as a native model or clean DXF, closed contours, one file per thickness, units stated on the file, and the flat pattern if you already have one.
  3. Quantity as two numbers: the quantity on this order and the annual volume. The process answer changes with the second one, not the first.
  4. The features that matter, marked: which holes position the part, which edges mate, which surfaces are datums, and the mating part if you have it.
  5. Tolerances on those features only, plus a general class in the title block. The reasoning and the classes are in our tolerance guide.
  6. Edge requirements if you have them: will the edge be welded, powder coated, anodized, or left visible in a humid environment.
  7. The downstream operations, whether you will form and weld in house or expect us to, and the edge break you want after cutting.
  8. Inspection and documentation: first article, material certificate, coating certificate, RoHS or REACH statements, and the PPAP level if this is an automotive program.

What to demand back: first article and material certs

A first article inspection is worth exactly as much as the discipline behind it. Ours is measured on a real part from the released nest, unclamped, at room temperature, and reported against a ballooned drawing, because a part that measures good while still clamped can move when the clamps come off. The protocol is in our first article inspection guide.

Material certification is cheap insurance. Insist on mill certificate traceability to the heat or lot, since the difference between 304 and a look-alike grade is invisible on the part and obvious in a salt spray cabinet, and on programs running to IATF 16949 or ISO 13485 it is not optional.

Ruijin Fenghui has been doing this in Dongguan for more than 23 years, across 200+ CNC machines and a sheet metal shop that runs laser, brake, weld and finish under one roof. We quote within 24 hours, the DFM review is free, and the prototyping guide explains what changes when you only need five pieces.

Engineering design review of a sheet metal part before laser cutting
Design review before the nest is released: the outline, the gas and the offset classes are one decision, and it is cheapest to make it here.排版发布前的设计评审:轮廓、气体与补偿分类是同一个决策,而在这一步做出它成本最低。

FAQ: what buyers ask us

Can you really hold ±0.05 mm on a laser cut part?

On thin material in the flat, yes, that is our routine band up to about 1 mm. We do not extend it to formed dimensions, to thick plate, or to a hole measured on a face you did not specify. If your requirement is ±0.01 mm we will still take the job, but we will price a machining operation after cutting.

Why do my holes come out about 0.1 mm small?

Almost always a single global kerf offset. Holes are cut slower and hotter than the external profile, so the effective kerf is wider on them, and one offset value cannot serve both. We run a separate offset per hole diameter band and verify it on a coupon from the same sheet lot.

Is nitrogen worth the extra line on the quote?

For stainless, yes, without qualification. For carbon steel that will be welded or powder coated, usually yes, because it deletes a grinding step that costs more in labor than the gas costs in consumables. For a hidden structural bracket, oxygen is the better buy, and we will quote both if you ask.

Can you cut copper busbars?

Pure copper is possible in thin gauges on a machine set up for it, and we will tell you honestly where our limit is, because high reflectivity sends energy back up the beam path. Brass we cut routinely. Above roughly 2 mm of pure copper we usually propose waterjet or machining rather than sell you a marginal laser job.

The parts fit in the flat and do not fit after bending. What changed?

Nothing went wrong; the tolerance changed owner. A dimension crossing a bend inherits press brake variation, springback and the K-factor used to unfold the flat, so a profile at ±0.05 mm becomes a flange at roughly ±0.25 to 0.50 mm. Move the dimension off the bend, or specify the feature in the formed state.

Why is one shop 30 percent cheaper on the same DXF?

Usually three assumptions you cannot see in the price: oxygen instead of nitrogen, no deburr or edge break included, and a nest at 60 percent utilization instead of 68. None of that is cheating, and all of it lands on your dock rather than their invoice. Ask which gas and what utilization the price assumes.

What do you need from me to quote in 24 hours?

Material and thickness, a clean model or DXF, both quantity numbers, and the features that control fit. Send those four and we will come back with a price, a process routing and a DFM comment. Send the mating part too if the panel has to drop onto something.

References

  1. ASME Y14.5, Dimensioning and Tolerancing. ASME
  2. Metrology, calibration and measurement uncertainty. NIST
  3. Dimensional metrology guidance. National Physical Laboratory
  4. The International System of Units (SI) and the definition of the metre. BIPM
  5. Coordinate measuring machine technology. Zeiss Metrology

Conclusion

More than 23 years of cutting, bending and machining metal has convinced us that most laser problems are specification problems wearing a process costume. The gas, the offset class, the nest and the edge break are four decisions a supplier makes on your behalf every time you send a DXF, and all four are cheaper to argue about before the nest is released than after the first article lands.

We run sheet metal laser cutting alongside metal stamping, machining, welding and finishing in one Dongguan facility, with more than 200 CNC machines, ±0.01 mm on machined features and ±0.005 mm on critical ones, working to IATF 16949, ISO 9001 and ISO 13485. Send us the drawing, the material, both quantity numbers and the mating part if you have one. You get a quote inside 24 hours, a free DFM review that includes the nesting study, and a plain answer on whether laser is the right process or a die would serve you better. If the honest answer is that your panel would be cheaper stamped, we will say that too. Talk to our engineers and we will start on it today.

一家德国音响设备厂商,在把图纸发给我们之前,先发来了一组照片。他们那块 2 mm 的 304 不锈钢前面板,420 × 260 mm,外轮廓是对的,孔位却出了问题:六个要套进机加底板螺柱上的 M4 间隙孔,在孔组的边角处最大偏了 0.35 mm;边缘还带着褐色氧化层,喷粉前必须擦洗;长轴方向还有约 0.6 mm 的弓形翘曲,装配时垫多少垫片都吸收不掉。

供应商并不是不认真。他们是在 CO2 机床上用氧气切割,整个面板族共用一张排版套料方案,而且对所有孔施加同一个切缝补偿值。这些做法在车间里都算常规操作,可每一项最后都会在装配环节变成钱。

我们改了四处:氧气换成氮气;孔单独设一套切缝补偿类别,不再用全局值;重新套料,把通风孔排到一条公共切割线上;再对真正决定配合的那六个孔补一道短的 CNC 工序。孔位从 ±0.20 mm 收到 ±0.05 mm,擦洗工序没了,板子下折弯机时是平的。气体成本上去了,后处理、废品和装配工时降下来得更多。

*(合成案例,细节已改动。)*

这个活就是本文存在的原因。我们的钣金制造指南在工艺层面比较了激光、冲床和水刀,如果你还在选工艺,那篇是起点。这一页只讲激光内部的事:光束对金属做了什么,辅助气体对边缘做了什么,切缝和锥度在哪儿吃掉你的公差,以及每个决定最后落到单价上是几分钱。它是写给已经确定需要钣金激光切割、并且想看清供应商正在替自己做什么决定的工程师的。

光纤激光器到底对金属做了什么

激光并不"切"。它把一条窄道熔化,然后一股同轴气流把熔体从板材底部吹出去。边缘质量、公差和成本的一切,都由三个量推导出来:光的波长、聚焦光斑处的功率密度,以及熔融材料能否可靠地离开切缝、而不是在背面重新凝固。

波长与吸收率:光纤为什么赢了

主导金属切割的是两种技术,它们的波长相差十倍。

属性光纤激光器CO2 激光器
波长1.06 至 1.08 µm,典型值 1070 nm10.6 µm
冷态钢上的吸收率明显更高,且熔池一旦形成便急剧攀升表面熔化前很低,在反射性合金上熔化后仍不稳定
聚焦光斑小,功率密度高同等光学件下更大,密度更低
1 至 3 mm 薄板上的速度同等额定功率下快 2 至 5 倍更慢
厚板现代高功率机型上可竞争至 20 mm 及以上历史上是厚板的选择
整机效率约 25% 至 35%约 5% 至 10%
反射性金属配合正确的穿孔策略可以加工差,且有真实的回反射风险
非金属差,光束会穿过许多塑料强,在有机物中吸收良好

吸收率就是全部的道理。在 1 µm 波长下,冷态钢吸收的入射能量是 10.6 µm 时的好几倍,而一旦形成熔池,吸收率还会陡然往上爬。这就是为什么光纤光源能在不锈钢和铝上稳定穿孔,而老一代 CO2 光源会犹豫、或者被反射光触发保护停机;也是为什么更小的聚焦光斑会把这个优势进一步放大。再叠上效率差距,就得到了每个买家都注意到的结果:光纤激光切割如今已是 8 mm 以下不锈钢和铝的默认报价方案,而 CO2 只是靠装机存量和非金属活路续命的旧工艺。

CO2 在透明塑料上还有活路,在老车间的特厚板上还有活路,在一些原始验证就绑死了它的切缝宽度和边缘颜色的老零件族上也还有活路。报价时我们会告诉你某个零件会不会从一种光源转到另一种,因为同一份 DXF 换一个光源,切出来的就不是同一个零件。

切缝宽度与切缝补偿

切缝就是光束切掉的材料。它不是一条线,而是一条槽,在钣金上通常宽 0.1 至 0.4 mm,并随料厚变宽,取决于材料、厚度、气体和焦点。你在激光切割钣金件上标注的任何尺寸,都是在这条槽已经被切掉之后才测量的,所以编程补偿量决定了你的成品尺寸。

材料与厚度辅助气体典型切缝说明
1.0 mm 304 不锈钢氮气0.10 至 0.15 mm干净,侧壁近乎平行
2.0 mm 304 不锈钢氮气0.15 至 0.20 mm我们的日常量产工况
3.0 mm 冷轧钢氧气0.20 至 0.25 mm更宽,因为反应额外放热
6.0 mm 冷轧钢氧气0.25 至 0.30 mm侧壁上开始显现锥度
2.0 mm 5052 铝氮气0.20 至 0.25 mm反射率和导热性把切缝拉宽
8.0 mm 冷轧钢氧气0.30 至 0.40 mm此时孔的上口与下口已能测出差别

做切缝补偿,以及它对孔径做了什么

CAM 系统把切割路径偏移半个切缝:外轮廓向外偏,让零件达到名义尺寸;孔向内偏,让孔张开到名义尺寸。我们在外来程序里最常看到的失效模式,是整张板所有特征共用一个全局补偿值。

切缝在一张套料里并不是恒定的。孔比长轮廓切得慢、停留时间更长,拐角处会减速并堆积热量,穿孔的工况也和贯穿切割不一样,所以相对于轮廓补偿值,孔会切得略宽一点。一个全局补偿值的结果是:外形尺寸接近名义值,而孔偏小。上面那块面板,孔就稳定偏小 0.10 至 0.15 mm。

我们分开跑补偿类别:外形轮廓一类,每个孔径段一类,槽一类。我们先从当批实际板材上切一块试片,测量、调整,再放行套料。如果你正在评估供应商,问一句他们用了多大补偿、有没有在试片上验证过。问这句话只要九十秒,而它就是"孔组装得上"和"孔组差一点装不上"之间的全部差别。

辅助气体:真正花钱的那个决定

激光切割钣金时,辅助气体干两件事:把熔体吹出切缝;以及要么保护切面不被氧化,要么故意往反应里加氧。第二件事是个岔路口,也是激光报价单上讨论得最少的一行。

氮气对氧气:你实际在买什么

氮气是惰性的。切面出来是亮白的、无氧化层,不用打磨就能焊,去个毛刺就能直接喷粉。它在碳钢上比氧气慢,而且是高压消耗,所以单件成本更高。

氧气不只是吹扫气,它是反应物。碳钢上铁会燃烧,这个反应提供了很大一部分切割能量,所以进给速度上去了,气体也更便宜。代价是切面上有一层磁铁矿层:焊前必须除掉,因为它会造成气孔和未熔合;喷粉前也必须除掉,因为它破坏附着力,还会透出一条深色线。

在不锈钢上,这个决定不是外观问题。切面处的铬与氧结合,边缘就失去了"不锈"的本钱,氧切割的边缘即便压在喷粉层下面,受潮也会泛锈斑,除非打磨回去再做钝化。凡是外露的、要清洗的、或者在沿海环境用的不锈钢,我们都不用氧气切。铝不一样:它的氧化层又硬又薄,氮气是标准做法,争论点在挂渣上。

辅助气体气体成本(相对)速度,3 mm 碳钢切面焊前处理涂装前处理最适合
氮气最高基准亮白、无氧化层只需去毛刺只需去毛刺不锈钢、铝、焊前准备、外观件
氧气最低快 30% 至 50%深色磁铁矿层打磨或喷砂打磨或喷砂碳钢、隐藏边缘、结构件
空气近乎为零,只需空压机薄板上接近氧气浅草黄到灰色氧化层打磨打磨或喷砂反正都要喷砂的薄碳钢

用空气切割,以及它什么时候没问题

空气切割是让洁净干燥的压缩空气通过同一个喷嘴。气体成本基本消失,薄碳钢上的速度也能和氧气掰手腕,所以对于无论如何都要喷砂加涂装的 1 至 3 mm 碳钢,它是个正当选择。它用在不锈钢上是错的,因为高温下的氧和氮会破坏你花钱买来的耐蚀性;用在焊前准备上也是错的。它还完全取决于空气质量:车间空压机带出来的油或水会落在切面上,然后被封在你的涂层底下。接受之前,先问问过滤和干燥做到什么程度。

我们是这样框算这笔账的:那么大的一块板,氮气的加价是按美分算的,而涂装前的人工擦洗是按分钟算的。分钟比美分贵,这就是为什么我们在不锈钢和铝上的默认报价都带氮气、而且不含二次边缘处理。

热影响区、挂渣与边缘锥度

热影响区有多要紧,以及什么时候不要紧

激光切割边缘上的热影响区很窄,薄板上是几十微米到零点几毫米,远小于等离子或火焰切割产生的。对大多数零件来说它无关紧要。有四种情况下它不再无关紧要。

第一是不锈钢敏化:切口周围的钢局部失铬,症状是几个月后边缘出现茶色锈迹。第二是铝。6061-T6 是人工时效的,紧邻切口的那一带经受的温度会让它过时效,所以局部屈服强度下降。当载荷路径从切口附近经过时这就很要紧,而且阳极氧化后会显出一圈光晕,因为软化带吃染料的方式不一样。我们的阳极氧化指南讲过为什么 5052 藏得住、6061 藏不住。第三是成形:紧贴折弯外侧的切割边缘可能开裂。第四是预涂板材,镀锌边缘的锌挥发会导致焊缝气孔。

除此之外——干燥机箱里的支架、安装板、内部机箱——热影响区只是规格书上的顾虑,不是零件失效。

挂渣、锥度与边缘垂直度

挂渣是没离开切缝、在背面重新凝固的熔体。软挂渣一擦就掉。硬挂渣得打磨,而且它是个值得追查的症状:气压偏低、喷嘴磨损、镜片脏了、焦点相对板材的位置不对、或者进给速度不在甜点区。如果一批零件里每一件都在同一条边上出现硬挂渣,那是工艺设置错了,不是材料的问题。

锥度是买家从来不做预算的一项。切缝不是一条平行的槽:它上宽下窄,薄板上大约差 0.02 至 0.10 mm,厚度增加时差得更多,所以正面的直径就不是背面的直径。ISO 9013 把这两项分开评级:垂直度或角度公差记为 *u*,切口粗糙度另记为 *Rz5*,完整的分级体系在我们的钣金公差标准指南里。对你的图纸来说:如果某个孔径是功能性的,就写明它测的是哪一面。

切面上的拖痕是第三个边缘特征,也就是人们说的激光边缘粗糙度。测量方法我们在表面粗糙度指南里单独讲,但就报价而言:2 mm 不锈钢的氮气切面是亮白的,不需要再做任何处理;6 mm 钢的氧气切面是带条痕、覆着氧化层的,永远都需要再处理。

特征极限:孔、槽、连接筋与拐角

最小孔径随厚度变化

全行业都在用的经验法则是:圆孔直径至少应为 1.0 × 料厚,而 1.5 × 料厚是质量和节拍都比较舒服的位置。低于 1 × T,熔体无法干净排出,挂渣会粘在孔里,圆度也跟着变差。

料厚最小孔径 Ø推荐孔径 Ø低于最小值会怎样
1.0 mm1.0 mm1.5 mm孔内挂渣,出口毛糙
1.5 mm1.5 mm2.5 mm穿孔慢,热量积聚
2.0 mm2.0 mm3.0 mm圆度漂移,出口毛刺变大
3.0 mm3.0 mm4.5 mm持续挂渣,锥度可见
4.0 mm4.0 mm6.0 mm穿孔主导节拍
6.0 mm6.0 mm9.0 mm考虑改用钻孔

当孔径小于料厚时,别硬逼光束:去钻它、冲它,或者挪到切割后的工序里做。3 mm 不锈钢上打 2 mm 的孔,那是钻床的活,把它当钻床的活来处理通常是省钱而不是费钱。判断哪些特征归激光、哪些归第二道工序,正是规范的报价前 DFM 分析的核心,而你把模型发给我们,这一步是免费的。

槽、连接筋与尖角

槽的宽度至少要 1.0 × T,在 1.2 至 1.5 × T 时更舒服。长度也有关系,因为长度超过宽度约八倍的槽会受热开始收口。如果你需要一条长通风槽,就用一条连接筋把它拆成两条短槽。

相邻切口之间的连接筋,是孔组悄悄出问题的地方。两个特征之间至少留 1.0 × T,如果其中任何一个有位置度要求就留 2.0 × T,因为薄筋会在光束下变形、把旁边的孔拖离位置。孔距零件边缘至少留 1.0 × T,2.0 × T 更好。

尖的内角是最后一个坑。激光理论上能做出接近零的圆角,但轴进角时会减速,停留会把角磨圆。内角上给个至少 0.5 × T 的圆角,如果那个角是承载的或是外观面,给 1.0 × T。小孤岛也要留意:一小块被切割线围住的骨架碎片会受热、翘起、然后撞上切割头。

Fiber laser cutting a stainless sheet metal panel
Fiber laser cutting a stainless panel: the coaxial gas jet clears the melt downward, and what does not leave becomes dross on the underside.光纤激光切割不锈钢面板:同轴气流把熔体向下吹出,凡是没被吹走的,就在背面凝成了挂渣。

我们能切多厚:碳钢、不锈钢、铝、黄铜、紫铜

钢、不锈钢与铝

能力不是每种材料一个数字。它是一段"边缘仍然良好"的区间,接着是一段"能切但慢、边缘质量要打折扣"的区间。

材料舒适的量产区间可切但更慢首选气体说明
冷轧与热轧低碳钢0.5 至 12 mm12 至 25 mm氧气或氮气氧气又快又便宜;边缘要焊接或涂装时用氮气
304 与 316 不锈钢0.5 至 8 mm8 至 12 mm氮气氧气会让你丢掉边缘的耐蚀性
5052 与 6061 铝0.5 至 6 mm6 至 8 mm氮气反射性强、导热快,厚度上来后容易挂渣
镀锌钢0.5 至 6 mm6 至 10 mm氮气锌蒸气需要抽风,还会让焊接变复杂
C260 与 C360 黄铜0.5 至 4 mm4 至 6 mm氮气锌烟;含铅牌号带来处置上的问题
C110 紫铜设置得当时 0.5 至 2 mm再往上要找专业厂家氮气见下面的反射率说明

黄铜与紫铜:反射率问题

紫铜把"拥有一台激光器的车间"和"能切紫铜的车间"区分开来。室温下紫铜对 1 µm 光的吸收率只有很小一部分,几乎全部反射,所以光束会一直反弹,直到形成熔池。这个转变是突变的,被反射的能量会顺着送它来的那条光路原路返回,一台没有回反射保护的机床可能在零点几秒内被损坏。这就是为什么很多供应商会悄悄拒掉紫铜,也是为什么一份铜排询价该好好谈一谈,而不是勾个选项框。

黄铜宽容得多,因为锌改变了吸收率和热行为,易切削牌号在几毫米以内切得很干净,代价是锌烟,以及在含铅牌号上有些客户接受不了的处置规定。纯铜超过约 2 mm,用水刀或机加做更合适,我们会在报价里直说,而不是卖给你一个勉强的激光活。

还有两个相关的情形会让人措手不及。抛光或镜面不锈钢的反射率远高于轧制面,所以你指定的那个外观面会改变切割参数;带 PVC 膜的板可以带膜切、切得很好,但膜会在切口处烧缩,还会贡献它自己的烟气。如果一家供应商从不问表面状态和涂层,那他报的是图纸里的材料,不是托盘上的材料。

我们敢写进合同的激光切割公差

下面是我们对切割特征承诺的区间:平面状态,板材经过规范套料与装夹,在室温下测量。

料厚轮廓公差孔径公差同一套料内的孔间距
0.5 至 1.0 mm±0.05 mm±0.05 mm±0.05 mm
1.0 至 2.0 mm±0.08 mm±0.05 至 0.08 mm±0.05 mm
2.0 至 3.0 mm±0.10 mm±0.08 mm±0.08 mm
3.0 至 6.0 mm±0.15 mm±0.10 mm±0.10 mm
6.0 至 10 mm±0.20 至 0.30 mm±0.15 mm±0.15 mm
10 mm 以上±0.30 mm 及以上±0.20 mm 及以上锥度主导结果

三条注意事项要跟着这张表一起看。它假设板材是平的、被夹紧的,因为带残余卷曲的板在切割过程中会移动;它假设关键零件排得离板材边角远一些,因为在 1.5 × 3 m 的台面上,热伸长最早显现在边角区域。还有,这是切割的数,不是机加的数:如果某个特征真的要 ±0.01 mm,我们靠切割之后再机加来保证。比这个区间再往下每压一毫米,都是用第二道工序换来的。

为什么切割公差和折弯公差是两个数

这个区分解决了大多数"零件装不上"的争论。完全落在平面内的尺寸,继承上面那张表。跨越折弯的尺寸,继承的是折弯机:回弹、料厚波动、模具磨损,以及展开时用的 K 因子。实际上,±0.05 mm 的切割轮廓做成法兰后大约变成 ±0.25 至 0.50 mm,单是 0.05 的 K 因子误差,就能让展开料每个折弯差出零点几毫米。

所以,只要几何允许,就把功能尺寸挪离折弯;实在挪不开,要么在成形状态下标注该特征、成形后再机加,要么把接头设计成能容在这条更宽的带子里。推导过程和按合金分的回弹数据在我们的折弯补偿指南里,图纸该怎么写、分哪几类在我们的公差指南里。

孔组上要写位置度,不要写坐标 ±。X 向 ±0.10、Y 向 ±0.10 的坐标标注,给出的方形合格区,对角距真实位置有 0.141 mm,而装配恰恰就失效在那个角上。客户指定了标准时,我们就按 ASME Y14.5 标准标注。

Press brake bending a laser cut blank
Press brake forming a cut blank: from this point on, every dimension that crosses the bend belongs to the brake, not to the laser.折弯机对切好的坯料成形:从这一刻起,凡是跨越折弯的尺寸都归折弯机说了算,不再归激光说了算。

套料、材料利用率,以及激光在哪儿开始不划算

套料就是零件在板材上的排布,而材料利用率通常是激光切割件单件成本里最大的单项。板材是按面积买的,骨架当废铁卖回去只值成本的一小部分,所以一张跑在 60% 的套料,等于把你付过钱的材料的 40% 扔掉了。

买家很少去拉的那个杠杆,是轮廓本身。我们评审过的一个支架族里,一段 20 mm 的装饰法兰和一个 10 mm 的装饰圆角,硬是把零件在板面上撑开了。把法兰收到 12 mm、把一个角改成直角,两个零件就能共用一条切割线,套料从 61% 提到 69%,也就是 8 个百分点,相当于每件少用约 12% 的材料。那 1 mm 的轮廓省下的钱,大致就把氮气加价抵掉了,而装配在意的东西一点没变。

共线切割省时间也省材料,因为一次走刀分开两个零件,而不是两次。和它打架的约束是轧制纹向:要求折弯垂直于轧制纹向,套料里就不能自由旋转,这通常要花掉 3 到 10 个百分点的利用率。折弯外露或承载时把这条说出来,不重要时就放手。更完整的单件成本图景在我们的 CNC 加工成本指南里。

激光在哪儿不再是最便宜的路

一旦某个简单轮廓的年重复量超过几千件,冲压模就能收回成本,单件价通常能降到原来的二分之一到三分之一,完整的盈亏平衡算账在我们的冲压与激光切割对比里。那副模具用什么钢做的,决定了这个低价能撑多久,这正是我们的冲压模具材料指南要讲的事。

切割之后:去毛刺与后处理顺序

每次激光切割都会在边缘留下点东西,可能是一圈 0.02 mm 的软挂渣,也可能是 0.10 mm 的硬毛刺。它是锋利的,它妨碍贴合,而且喷粉盖不住它,因为涂层会从锋利边缘往回缩。

我们报价的工序顺序是:切割 → 去毛刺并倒角 → 成形 → 焊接 → 焊缝区再去毛刺或打磨 → 表面处理 → 涂装。成形前去毛刺,是为了不让毛刺在折弯模上压出印子、或者在弯角外侧开裂;焊前去除氧化层是防止气孔的关键,这在钣金焊接指南里讲得更深。

方法按零件分。振动光饰适合小件,边缘均匀,但它会喷丸软化铝、也会把你本来要保留的尖角磨圆。通过式砂带与刷辊机适合平板件,倒角重复性好,上面那类面板我们就是这么干的。手工是做外观用的,重复性最差;不锈钢上的电解抛光一步就能去掉热影响区和游离铁。

要规定倒角量,不要写感觉。"锐边倒角 0.1 至 0.2 mm"是可采购、可测量的;"去除所有毛刺"不是,这就是为什么两家供应商对同一条去毛刺要求报出不同的价。可选方案和成本在我们的去毛刺指南里,涂装那一侧在表面处理指南里。

Surface finishing of laser cut sheet metal parts
Surface finishing after cutting: an edge that is broken and oxide free before coating is the difference between a panel that passes and one that telegraphs its cut line.切割后的表面处理:涂装前把边缘倒好角、清掉氧化层,决定了一块面板是判合格,还是把切割痕透出来。

合成案例:这些改动对数字做了什么

这就是文章开头那块 2 mm 的 304 不锈钢面板,现在把数字附上。

*(合成案例,细节已改动。)*

项目改前:CO2 配氧气、单一补偿改后:光纤配氮气、分类补偿
孔组位置±0.20 mm,最差 0.35 mm±0.05 mm,三坐标验证
单张板上的孔径散差0.15 mm0.04 mm
涂装前的边缘处理人工擦洗加砂带,约 6 分钟/件仅去毛刺,约 0.5 分钟/件
切割后的平面度约 0.6 mm 弓曲0.15 mm 以内
废品与返工率9%0.8%
装配贴合率每 6 块有 1 块要手工返修无需返修
单价指数10095

四项改动带来了这些结果。氮气去掉了氧化层、擦洗工序,以及把板子顶弯的那片热分布。按孔径段分设的补偿类别消除了系统性偏小。把通风孔排到公共切割线上的那次重新套料,把利用率从 61% 提到 69%,大致就把氮气加价抵掉了。而决定配合的六个孔,在切割之后上加工中心收尾——±0.01 mm 这个数,老实说就是从那儿来的。这类前面板占了我们音响设备业务的大头:轮廓没问题,孔组有问题。420 × 260 mm 的面板落在我们铣削中心 1000 × 500 × 300 mm 的行程范围内,所以只是一个短程序;需要复合角度的零件,就要转到五轴单元去,而五轴单元的上限是 750 × 650 × 500 mm 行程、Ø500 × 400 mm 的零件。

这里没有一样需要什么稀奇设备。需要的只是有人把套料、气体和补偿当成同一个决策,而不是三个默认值。

询价时要随附什么,以及要要回什么

八项材料能让你在 24 小时内拿到可比较的报价。其中两项——数量和关键特征——决定了激光到底是不是正确的工艺。

  1. 材料、状态与准确料厚,加上表面状态:2.0 mm 的 304 2B,1.5 mm 的 5052-H32,以及板材到货时带的是 PVC 膜、拉丝面还是镜面抛光。
  2. 几何:原生模型或干净的 DXF,轮廓闭合,一个料厚一个文件,文件上写明单位,如果已经有展开图也一并提供。
  3. 数量给两个数:本单数量,以及年用量。工艺答案是跟着第二个数变的,不是第一个。
  4. 重要的特征,标注出来:哪些孔决定定位,哪些边配合,哪些面是基准,有配合件的话也一起给。
  5. 只给这些特征标公差,标题栏里再给一个通用等级。推理过程和等级划分在我们的公差指南里。
  6. 边缘要求,如果有的话:这条边是要焊接、喷粉、阳极氧化,还是就那么外露在潮湿环境里。
  7. 下游工序:成形和焊接你们自己做,还是指望我们做;以及切割后你要的倒角量。
  8. 检验与文件:首件、材质证明、涂层证明、RoHS 或 REACH 声明,如果是汽车项目还有 PPAP 等级。

要要回什么:首件与材质证明

首件检验的价值,恰好等于它背后的纪律。我们的首件是在已放行的套料上取一件真实零件,松开装夹,在室温下测量,并对照气泡图报告,因为"还夹着的时候测着合格、松开夹子却跑掉"的零件是存在的。整套流程在我们的首件检验指南里。

材质证明是便宜的保险。坚持要可追溯到炉号或批号的钢厂质保书,因为 304 和某个长得像的牌号之间的差别,在零件上看不出来,在盐雾箱里一目了然;而在按 IATF 16949 或 ISO 13485 运行的项目上,这不是可选项。

锐金峰汇在东莞干这行已经有 23 年以上,手上有 200 多台 CNC,还有一个把激光、折弯、焊接和表面处理放在同一屋檐下的钣金车间。我们 24 小时内报价,DFM 评审免费,而打样指南会讲清楚你只要五件时有什么不一样。

Engineering design review of a sheet metal part before laser cutting
Design review before the nest is released: the outline, the gas and the offset classes are one decision, and it is cheapest to make it here.套料放行前的设计评审:轮廓、气体和补偿类别是同一个决策,而在这时把它定下来成本最低。

常见问题:买家问我们的问题

激光切割件上你们真能保 ±0.05 mm 吗?

薄料、平面状态下,能,这是我们到约 1 mm 为止的常规带。我们不把它延伸到成形尺寸上,延伸不到厚板上,也不接受一个你没指定测量面的孔。如果你的要求是 ±0.01 mm,这活我们照样接,但我们会把切割之后的一道机加工序报进价格里。

为什么我的孔出来大概小 0.1 mm?

几乎总是因为单一全局切缝补偿值。孔比外形轮廓切得慢、温度更高,所以有效切缝在孔上更宽,一个补偿值伺候不了两边。我们按孔径段分设补偿,并在同一批板材的试片上验证。

报价上多出来的那行氮气费用值吗?

不锈钢上,值,不用加任何限定条件。要焊接或喷粉的碳钢上,通常也值,因为它删掉了一道打磨工序,那道工序的人工费比气体的消耗费高。对隐藏的结构支架,氧气更划算;你开口问,我们两个都报。

你们能切紫铜排吗?

纯铜在薄规格上、在有相应设置的机床上是可行的,我们会老实告诉你我们的极限在哪儿,因为高反射率会把能量顺着光路送回去。黄铜我们常规切。纯铜超过约 2 mm,我们通常建议水刀或机加,而不是卖给你一个勉强的激光活。

零件在平面状态下装得上,折完就装不上了。哪儿变了?

没出什么错;是公差换了主人。跨越折弯的尺寸继承的是折弯机的波动、回弹,以及展开时用的 K 因子,所以 ±0.05 mm 的轮廓做成法兰后大约变成 ±0.25 至 0.50 mm。把尺寸挪离折弯,或者在成形状态下标注该特征。

为什么同一份 DXF 有家便宜 30%?

通常是三个你在价格里看不见的假设:用氧气而不是氮气;不含去毛刺或倒角;套料跑在 60% 而不是 68%。这些都不算作弊,但全部会落到你的收货台上,而不是落到他们的发票上。问清楚这个价格假设的是哪种气体、多少利用率。

要 24 小时报价,你们需要我给什么?

材料和料厚、干净的模型或 DXF、两个数量、以及决定配合的特征。这四样发过来,我们会回给你一个价格、一条工艺路线和一份 DFM 意见。如果面板要落到别的东西上,配合件也一起发。

参考资料

  1. ASME Y14.5,尺寸与公差标注。ASME
  2. 计量、校准与测量不确定度。NIST
  3. 尺寸计量指南。National Physical Laboratory
  4. 国际单位制(SI)与米的定义。BIPM
  5. 三坐标测量机技术。Zeiss Metrology

结语

23 年以上的切、折、铣,让我们确信:大多数激光问题,都是穿着工艺外衣的规格问题。气体、补偿类别、套料、倒角量——这是你每发一次 DXF,供应商就替你做一次的四个决定,而所有这四个决定,在套料放行之前争论,都比首件落到你桌上之后再争论便宜。

我们在东莞的同一厂区内同时做钣金激光切割、金属冲压、机加、焊接和表面处理,拥有 200 多台 CNC 机床,机加特征 ±0.01 mm、关键特征 ±0.005 mm,按 IATF 16949、ISO 9001 和 ISO 13485 运行。把图纸、材料、两个数量发给我们,有配合件也一起发。你会在 24 小时内拿到报价,拿到一次包含套料研究的免费 DFM 评审,还有一句大白话:激光到底是不是正确的工艺,还是开一套模对你更划算。如果老实答案是你的面板冲压更便宜,我们也会这么说。和我们的工程师聊聊,我们今天就开工。

Get a QuoteFree DFM · 24h