- In Use
- Technical Details
Laser Dicing Machine for PCD
The Coborn LD2 laser has been developed for cutting and shaping PCD, CVD, tungsten carbide and some types of PcBN into smaller blanks. It can also be used to cut holes.
In comparison to electrical discharge wire cutting, the LD2 has five key advantages:
- Increase in production rate
- Low running costs
- Ability to cut holes
- Increase in yield
- Dry operation
The LD2 laser system consists of 6 main components:
- YAG laser generator and laser head
- Precision X-Y-Z positiioning system
- X-Y table/laser interface control system
- Gas supply from bottles or compressor and dryer
- Water chiller for the laser
- Enclosure exhaust system and filters
The most common application for the laser is cutting carbide backed PCD mother discs into smaller pieces. The laser work table will accommodate up to 4 discs each up to 95mm diameter, which in turn can accommodate a maximum collet size of 76mm. Different sleeves can be supplied for other disc sizes.
The YAG laser is either gas-assisted (N2) or uses compressed air and will cut standard thickness PCD at the following typical speeds:
- 1.6mm 80-100mm/min
- 2.0mm 60-80mm/min
- 3.2mm 15-20mm/min
- 4.5mm 5-10mm/min
The standard ‘Coborn’ controller reads the cutting pattern directly from the DXF drawing file.
As an alternative, a Fanuc™ control system can be supplied.
The LD2 in use
The laser is extremely simple to operate:
- Draw the required cut pattern on a CAD system
- Upload the DXF file to the LD2 controller via the network or a memory stick
- Recall the required laser parameters for the material to be cut, such as:
- cutting speed
- power, etc.
- Close the door; start the cut
- On completion, interlocks prevent the door being opened until fumes have been safely extracted by the filter
- A large PCD disc can be cut in a few minutes rather than the hours taken by wire EDM
- The pieces remain keyed together after cutting and can be separated by finger pressure
- The pieces should be cleaned before brazing to remove the soot & kerf debris from the cut surfaces
The Increase in Yield
The reduced kerf width compared to wire EDM cutting enables an increase of around 15% in the number of pieces that can be cut from a disc.
Cutting Tungsten Carbide
The LD2 has been shown to produce significant advantages in producing near net shape forms in deep profile woodworking tools from cemented carbide plates. Angle cutting to create a tool clearance, for example, can be achieved (in the Y direction) by mechanically tilting the laser head between 0 and 45 degrees.
Typical Speeds: 2mm thick - 60mm/min 5mm thick - 25mm/min
Low cBN content PcBN has a significantly lower thermal conductivity than PCD and may crack. Therefore, theLD2 is not recommended for cutting this type of PcBN. Medium cBN content PcBN can be cut using special cutting strategies. High cBN content PcBN can be cut similarly to PCD.
Cutting HolesThe LD has an absolute advantage over wire EDM machines in that it can cut holes.
|- Machine type||Laser dicing machine for PCD||Laser dicing machine for PCD and thick tungsten carbide|
|- Dimensions - main machine (w x d x h)||1,312mm x 2,064mm x 2,300mm||1,312mm x 2,064mm x 2,300mm|
|- Total machine weight||1,200kg||1,250kg|
|- Total connected load||20kW / 23kVA||20kW / 31kVA|
|- Laser type||YAG||YAG|
|- Gas assistance||Normally bottled Nitrogen||Nitrogen or compressed air|
|- Laser wavelength||1064nm||1064nm|
|- Average output||300W||400W|
|- Peak power||20kW||20kW|
|- Laser head tilt facility||Yes - manually adjusted and set||Yes - manually adjusted and set|
|Maximum laser head tilt||45 degrees||45 degrees|
|- CNC table travel - X axis||300mm||300mm|
|- CNC table travel - Y axis||300mm||300mm|
|- Motorised vertical table travel - Z axis||150mm||150mm|
|- Collet provided in standard table||4||4|
|- Collet maximum diameter||76mm||76mm|
|- Work table weight loading||10kg||20kg|
|- Typical kerf width on PCD||0.1 - 0.15mm||0.1 - 0.15mm|
|- Typical gap between laser nozzle and work piece||0.5 - 1.0mm||0.5 - 1.0mm|
|- Typical cutting speed on 1.6mm thick PCD/WC||80 - 100mm/min||100 - 120mm/min|
|- Coborn control system accepts DXF files directly||Yes||Yes|
|- Can be networked||Yes||Yes|
|- Internet access for diagnostics||Yes||Yes|
|Optional extras - not a complete listing|
|1. Fanuc™ control system||Available||Available|
|2. Larger laser for cutting thicker materials||Available||Included|
|3. Heavy duty X-Y table for pallets||Available||Included|