Advanced Manufacturing Processes

and Technology
Karim Habbas B122608, Mark Poulton B125359

Project Brief: Proposal to investigate the feasibility and design an automated system to
use laser technologies for producing aluminium aircraft window frames.

14MMC600

Contents
1.0 Introduction .......................................................................................................... 3
2.0 Technology and Equipment .................................................................................. 4
2.1 Laser Source .................................................................................................... 4
2.2 Beam Delivery Methods.................................................................................... 6
2.3 Beam Focusing Optics / Equipment.................................................................. 6
2.4 Process Mechanism & Automation Technologies ............................................. 7
3.0 Conceptual Design ............................................................................................... 7
3.1 Process Flowchart .......................................................................................... 10
4.0 Critical Evaluation & Recommendations ............................................................ 11
5.0 References ......................................................................................................... 13
6.0 Appendix A: Production Volume Model .............................................................. 14

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1.0 Introduction
The task assigned is to propose an automation process utilising laser cutting to finish
an aluminium aircraft window frame, see Figure 1. The dimensions of the component
are 350mm by 250mm, with a thickness of 3mm. A target of 600 units per shift has
been set.
This report will recommend an automation process in order to meet the production
quota, whilst outlining the technology behind the operations. A critical assessment of
the feasibility as well as a cost benefit analysis will also be included to evaluate the
viability of automation to the company.

Figure 1: Window Frame

2.0 Technology and Equipment

2.1 Laser Source
There are several types of lasers that can be used for cutting and finishing. In the
case of the aluminium window frames, this report recommends the use of a
continuous wave fibre laser, mounted to a programmable robotic arm to meet the job
specification.
A CO2 laser is not suitable for this operation, as the material is aluminium which is
highly reflective. With a wavelength of 10.6m the beam would be reflected back,
damaging the laser delivery head and having little effect on the workpiece. A pulsed
Nd:YAG laser would be more suitable in this instance, ideal for drilling the 4x8mm
through holes, however, the operation is not as accurate, or efficient when it comes
to cutting or edge trimming.
High power fibre lasers operating in continuous wave mode offers a great potential in
improving the cut quality and productivity of highly reflective materials due to the
better absorption of 1m laser radiation. The initial pulse will create high energy
concentrations, which is necessary in order to generate enough power to overcome
the reflectivity of the aluminum. Technically, operationally and commercially there
any many distinct advantages of using a fibre laser over other laser types
summarised in Table 1 below:

Table 1: Laser Types

The disadvantage of fibre lasers is apparent when manipulating thicker materials,

typically above 5mm, cutting speeds, and hence cutting quality, is lower when
compared to CO2 and Nd:YAG lasers.
Full specifications of the 3kW multimode, Continuous Wave, Ytterbium fibre laser to
be used can found in the Figure 2 below:
4

<50m

Spot size
2

M
Beam Parameter Product (BBP)
Wavelength
Lens focal length
Diameter of unfocused beam

15
4 mm*mrad
1.075m
190.5mm
100 m

Nozzle diameter
Nozzle standoff
Gas used
Compressed Gas Pressure
Gas Volume

1.5mm
0.8mm
Nitrogen (N2)
14bar
3
15m /h

Laser Power
Max Cutting Speed
Focal Point Standoff
Kerf Width

3kW
7.5m / min
0mm
0.24mm

Figure 2: Laser Specifications

Once installed, the laser cutting process can be optimised as follows:

1.
2.
3.
4.
5.

Start with laser setting that gives best performance

Increase cutting speed until cut quality decreases
Adjust power (typically increased power but can be decreased)
Adjust focus (both up and down)
Adjust assistance gas pressure (up and down)

Where steps 3, 4 and 5 all are aimed at improving cut quality.

2.2 Beam Delivery Methods

In utilising a fibre laser, the simplicity of delivering the laser through an optical fibre,
of up to 20m in length, allows for a simple but effective beam delivery method to the
laser head. An external laser coupling optic can be used for a fibre laser, or the
delivery fibre can be spliced into the lasing fibre. The disadvantage of an internal
splice is that it is difficult to repair. The beam coupling method, see Figure 3 enables
fibre replacement with a quick changeover, hence reducing downtime (Shannon,
n.d.).

Figure 3: Laser coupling unit

Furthermore, the delivery fibre has minimal power loss due to very efficient total
internal reflection of the laser inside the fibre. Resulting in running cost savings of up
to 30% when compared to using CO2 lasers (Laser Photonics, n.d.) .
Mountable
Proximity Sensor

2.3 Beam Focusing Optics /

Equipment

Collimated light, created by pumped

arrays of diodes, are amplified and
focused by the optics inside the laser
head onto the material to be cut. Figure
4 shows a schematic of a 90-degree
focus head, using a collimating lens,
45o reflector, focusing lens and cover
slide to focus the beam to the required
cutting parameters (Shannon, n.d.).
Figure 4: Collimating Lens
Due to the fact aluminium is reflective;
a beam splitter will be integrated into the focusing equipment to prevent blowback.
An advantage of using a focus head like this is the adjustability in manufacturing,
something which may be harder to achieve if an inline focus head was to be selected.
Furthermore, proximity sensor vision system can be directly mounted on the top of
the head, and used by the computer controlled automation system as a method of
validation.
Likewise, orientation of the head to the part and its size is important to achieve
operational efficiency. The size of the laser focusing optics is not an issue when
manufacturing the part due to the variable degrees of freedom, and programmed
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cutting path when coupled with a robotic manipulation arm. If a laser machine was to
be used, size of the head could hinder the cutting operation.
For a high quality cut the spot size should be less than 50 micrometres. The small
spot size increases the power density resulting in a small kerf width to minimise, and
potential prevent dross contaminating the work-piece by minimising the material cut.
While the material is still molten, a 0.5mm diameter gas jet nozzle - coaxial to the
laser head - ejects the molten material. In this instance, Nitrogen will be used as the
inert gas to provide optimal environmental conditions. The dross-free cutting range is
larger at higher laser powers due to the increased incident intensity, thus further
justification for adopting a 3kW fibre laser. If dross free cutting cant be achieved,
control mechanisms will be put in place to eliminate the need for post-treatment.

2.4 Process Mechanism & Automation Technologies

Automation will involve a 5 axis robotic actuator, with a mounted laser head, in
conjunction with a 3 axis work bed and end effector, will facilitate the actual laser
cutting of the part. The rest of the process, involving feeding in the unworked, and
delivering the worked part will be PLC controlled via a conveyor system. The full list
of equipment to be used can be found below in Figure 5:
Robot Arm
Laser Head
Fibre Laser Delivery System
Part Ejection Flipper
Proximity Sensor Vision System
Pneumatic work bed
Conveyor belt with moulded cavities
Pneumatic 4 jaw end effector, with force sensor
Delivery shoot
PLC Control Unit
Figure 5: Process Mechanisms

Alternatively a laser cutting machine could be used. However this is more expensive
due to higher set up and running costs, along with more complex and longer
automation times, due to the need for a twin pallet exchange. This suggests that a
robot head and conveyor system that is configured to meet the job specification is
more suitable because its more cost effective, efficient and commercially viable.

3.0 Conceptual Design

A series of annotated 2D sketches will now illustrate the proposed automation design
to produce the aluminium window frames. Figure 6 below shows the full concept.

3. Once the PLC receives the feedback signal from the end
effector confirming the part is secure, this then activates the
laser cutting operation. See Figure 8.

1. PLC calculates and verifies if part has arrived through

use of proximity sensor, mounted above, and alignment
with cavity walls of conveyor belt. Once the system
validates the part has been delivered onto the work-bed
zone, conveyor stops and the flipper remains contracted,
i.e. out of the way.

The robot arm has a large enough envelope to cover the

whole area, however due to the singularity within robotic
arms; the far curve may be difficult to reach. To resolve
this, the part can be rotated allowing for the laser to
continue to cut the other half.
Fibre Laser Head
Flipper

5 Axis Robotic
Manipulation
Arm

Conveyor belt with cavities

4 jaw pneumatic end
effector

3 Axis Work-bed

Delivery Shoot

4. Finally, when the laser cutting is

complete, the raised end effectors
disengage with the part and move
downwards inside the work bed. This then
allows the flipper to push the completed
work part into the delivery shoot. See

Figure 6: Automation System

2. With the part now delivered on the bed, the use of a

pneumatic 4 jaw, gas controlled end effects with force
sensors that accurately locate and join to the part from
the underside eliminating interference with the laser
cutting operation. See Figure 7.

Figure 7, 8, and 9 below illustrates further details of the automation process.

The application of the end effectors is
applied to the four corners to reduce
randomness by providing better corner
distribution. The end connectors are
specially designed with a V shaped indent
to effectively grip the inner flange. The use
of a pneumatic force sensor eliminates the
risk of not having the part orientated in the
correct position before the laser cutting is
to commence.

Figure 7: End Effector Detail

Vertical

Pictured are the two orientations of

the laser head to complete the cutting
and edge trimming. The yellow cutting
path shows the initial cuts that can be
made with the head in a vertical
position. Once the four holes are cut,
and the perimeter is edge trimmed,
the manipulation robot positions the
laser head horizontally to edge cut the
internal features. Furthermore, the 3
axis of the bed allows the part to be
angled for dross free cutting.

Horizontal

Figure 8: Laser Cutting Path Detail

The blue square indicates the work-bed surface.

After the PLC validates the cutting operation is
complete, the laser is switched off, and the end
effectors released. The flipper, illustrated in
orange, then pivots about a point to knock the
completed aircraft window component down a
delivery shoot.

Figure 9: Part Ejection Detail

3.1 Process Flowchart

The concept designs in conjunction with Figure 10 help to further describe the
proposed automation process.

The use of a proximity sensor, with

a fast feedback time is used in
order to verify that the part has
arrived. The robotic arm can then
move accordingly to start the
cutting process at the required
speed.
A guard will be utilised during the
cutting phase, to shield the dross
generated from contaminating the
quality of the product. Use of the
full 8 axes will allow the direction of
dross to be controlled eliminating
post treatment processes.
Once programmable cut path has
been completed, the laser is turned
off, the griping end effectors are
removed and the part is flicked off
the work-bed down the delivery
shoot.
Figure 10: Automation Process

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4.0 Critical Evaluation & Recommendations

Introducing automation into a manufacturing process is only viable when the
products produced are either of a better quality or produced in a larger quantity. In
the case of this process, the benefit would be from more production of units per shift.
The proposed 8 axis (5 axis of the head plus 3 of the workbed) automation system
includes a robotic actuator, with a large operating envelope and an end effector bed
system in order to manipulate the parts on the assembly line, achieve the correct
profiling of shapes and factor in the flexibility of the profile. In combination with an
intelligent force sensor end effector, the laser cutting process will involve a
continuous wave fibre laser for high precision and high cutting speeds to meet the
tolerance and volume requirements.
Due to the material properties, aluminium requires several kilowatts of power in order
to cut the material so that the reflectiveness of the material is overcome. However
with such high power settings there is an inevitable risk of spatter and dross. To
mitigate the risk of unacceptable quality, the fibre laser will create high energy
concentrates that will significantly reduce reflectivity to approximately 20% resulting
in better power distribution and superior cut quality to the 0.1mm tolerance. This
minimises the heat affected zones meaning the aluminium is less prone to warping
when compared to other laser sources. Prevention of defects is critical.
Furthermore, the benefit of fibre delivery is that it can be easily delivered to the work
surface via mounting onto the manipulation arm. In turn the manipulation arm, and
end effect work-bed can be easily and flexibly programmed, to achieve any 3D cut.
Table 2 below estimates the cost of automation.

Table 2: Capital Investment

Although automation requires a capital investment, this system can be

reprogrammed in the future and adapted for a variety of other processes and
production units. Compared with the more expensive laser machine system (>250k
investment) this system provides better operational flexibility and productivity. The
laser machine may offer tighter production quality, but the tolerances achievable with
the proposed system are well within the specification.

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In terms of production volume, using a fibre laser cutting process the manufacture of
the components will take considerably less time, especially when compared to
milling. Assuming a 3kw fibre laser will achieve a minimum cutting speed of
7500mm/min for 3mm aluminium (Hypertherm, n.d.) a finishing cutting time of 18
seconds per unit can be achieved and a total Takt time of 34 seconds (see Figure
11 below).
Maximum Production Volume

Goal Seek Target

Holes
Outer edge
Inner feature
Total Cutting Distance per part (mm)

32
1180
940
2152

Holes
Outer edge
Inner feature
Total Cutting Distance (mm)

Cutting Speed of Laser 3mm Al (mm/ min)

Laser Power Output (kW)

7500
3

Cutting Speed of Laser 3mm Al (mm/ min)

Laser Power Output (kW)

32
1180
940
2152
4035
TBD

Total Time to laser cut per Part (s)

18

Total Time to laser cut per Part (s)

32

Conveyor belt delivery

Proximity sensor verification
End effector actuation (clamping)
End effector actuation (de-clamping)
Part removal via Flicker
Total automation time per part (s)

2
1
7
4
2
16

Conveyor belt delivery

Proximity sensor verification
End effector actuation (clamping)
End effector actuation (de-clamping)
Part removal via Flicker
Total automation time per part (s)

2
1
7
4
2
16

Total Takt Time per Part (s)

34.00

Total Takt Time per Part (s)

48.00

Target No. of Units per Shift

Shift Duration (hrs)
Shift Duration (s)
Max Units per shift

600
8
28800
847

Target No. of Units per Shift

Shift Duration (hrs)
Shift Duration (s)
Target Units per shift

600
8
28800
600

Figure 11: Production Volume Achievable

This results in an increase from 600 to 847 units per shift (for in depth calculations
refer to Appendix A). In using a 3kW laser the scalability of the production can be
controlled, by increasing or reducing the laser power in order to control the cutting
speed. It is important to note that a cutting speed of 4035mm / min must be achieved
in order to meet production quota, unless the automation of the system can be
optimised and made quicker than assumed here. This would potentially allow a 1.5
or 2kW laser to be used, but the production system may be in danger of not meeting
the quota, and be unable to ramp up production if required.
The company must see this as an investment opportunity, with relatively quick
payback due to the high volume of products produced. Furthermore the product is
readily flexible, able to be used for other operations in the future with ease, and is
modular - allowing other items to be added should they be required for
manufacturing in future projects. The overarching benefits of adopting this system
are its flexibility, productivity and future potential.
Hence it is the recommendation of this report for the company to invest in the
aforementioned automation and laser cutting technologies.

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5.0 References
Hypertherm, n.d. HyIntensity Fiber Laser HFL030. [Online]
Available at:
http://www.hypertherm.com/en/Products/Automated_cutting/Laser_systems/Fiber_la
ser/hfl030.jsp#1
[Accessed 29 11 2014].
Laser Photonics, n.d. Cost Comparison: Fiber Laser vs. CO2 Laser High Power
Cutting. [Online]
Available at: http://laserphotonics.com/docs/Fiber_v_CO2_highpower.pdf
[Accessed 05 12 2014].
Preco Incorporated, n.d. Preco Robtoic Cell. [Online]
Available at: http://www.precoinc.com/systems/robotic-cell/
[Accessed 23 12 2014].
Shannon, G., n.d. LASER BEAM DELIVERY AND FOCUSING OPTICS. [Online]
Available at: http://www.ffjournal.net/item/11140-laser-beam-delivery-and-focusingoptics.html
[Accessed 29 11 2014].

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6.0 Appendix A: Production Volume Model

14