Page 22 - MetalForming December 2017

When Laser Blanking Is the Best Bet
cutting through 1-mm-thick aluminum, mild steel, AHSS and surface-sensitive materials at speeds to 2 m/sec. This makes laser blanking a viable and com- petitive choice for part volumes to 100,000/yr.
Laser blanking may seem unsuitable when producing blanks through paid- for dies on a mechanical press running at 30 to 40 strokes/min., with minimal scrap and little tool changeover. But,
remember that a laser-blanking line can accommodate multiple cutting heads—two lasers are common, but more are available on custom machine configurations. LaserCoil can accom- modate as many as eight heads, for instance.
In addition, stamping requires die maintenance, an important consider- ation given the increased wear rates common when blanking high-strength
steels. For laser blanking, setting up a new job is a matter of loading a new coil and a new program, and pushing cycle start versus the time required for a die change when stamping blanks. A laser setup also makes drop-in orders and test runs simple to accommodate. Work-in-process ( WIP) is reduced, and the elimination of dies creates addi- tional floor space.
Laser Blanking Cuts Waste
It’s hard to fathom that scrap from producing automobile bodies-in-white can range from 20 to 40 percent, inclu- sive of rejected parts. With raw-material costs increasing, and the premium prices attached to some high-strength steels, all steel processors have scrap- reduction goals. Software advance- ments give laser cutting great potential for cost savings through the ability to maximize raw-material usage and reduce scrap.
Analysis of a 25-part list from an auto- motive program with an annual volume of 100,000 cars revealed that a laser- blanking manufacturer processing high- strength steels—stamping and shearing various chevrons, trapezoids, rectangles, and some developed and semi-devel- oped pieces—may expect a total 5-yr. material cost of nearly $237 million. However, with the nesting capability offered by laser blanking as well as excel- lent performance in cutting advanced steels, this figure can be reduced to $217 million. And, don’t forget about fewer trips to the recycling yard.
WSP realized some of these material savings through these advantages, and also found that it could be flexible with its cutting strategy.
“We refer to it as a free-style approach,” says Fred Weddington, WSP vice president of sales. “The nesting opportunities for real-yield savings are incredible.”
This results from the laser-blanking process’ ability to produce fully devel- oped blanks, which are much closer to their final, formed shape than their mechanically produced counterparts. Lasers enable nesting and common- line cutting, and even allow smaller
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20 MetalForming/December 2017
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