ap-3-11.dvi Acta Polytechnica Vol. 51 No. 3/2011 Relation between Cutting Surface Quality and Alloying Element Contents when Using a CO2 Laser J. Litecká, J. Fabianová, S. Pavlenko Abstract This paper deals with the influence of material content on changes in the quality parameters of the cutting surface when cutting with a laser. The study focuses on experiments to find the effect of material structure and cutting parameters on surface roughness, Vickers microhardness and precision of laser cutting. The experimental results are shown in graphs which illustrate the suitability of materials for achieving required cutting surface quality parameters. These results can be used for optimizing production in practical applications using a laser cutting machine. Keywords: laser cutting, alloyed steel, unalloyed steel, surface quality, cutting parameters. 1 Introduction Laser material cutting is a progressive technology. However, due to high cost and high energy use, it is not aswidely used in industry as traditionalmaterial cutting technologies. This progressive technology of- fers a wide area for researchers. It is necessary to focus on optimization and reengineering, using non- conventional ways of machining. There are nowadays wide opportunities for using lasers in technological applications. Laser processing is a physical way of processing that is very clean and has high energy density. It is able to focus energy on a very small surface. It is very fast, and it can reduce material requirements. 2 Cutting surface quality evaluation parameters after laser beam cutting Thequality of the cutting area is determinedby three basic cutting parameters: cutting speed; gap width and surface quality. The cutting speed should be as high as possible; the gap width should be as small as possible, and the surface quality is determined by Ra based on STN, ČSN and Rz based on DIN, EN ISO 9013. This standard is based on the English text of the European Standard EN ISO 9013:2002 “Thermal cutting—Classificationof thermal cuts— Geometrical product specification and quality toler- ances”. The cutting area using a laser is characterized by analogy with most high-power cutting technologies. A grooved track is createdby laser cutting as a result of the cyclic phase of the energy beam in interaction with the material by oscillation of hot-melt flow. For certain types of material (mild steel, corrosion-resistant steel, ceramics, composite mate- rials, titanium, plastics) the quality of surfaces cut by a CO2 laser with an additive gas, based on EN ISO 9013, can be characterized by the following val- ues: a) perpendicularity or angularity tolerance, u; b) mean profile height, Rz. The following characteristic values may be used in addition: c) drag, Δn; d) melting of the top edge, r; e) possible occurrence of dross or melting drops on the lower edge of the cut. Fig. 1: Parameters for evaluating the cutting surface dur- ing laser cutting: Rz – mean profile height, n – drag line, α – angle of beamdeviation, r – radius, w – groovewidth, S – material thickness, Δs – thickness reduction, M – measured area 39 Acta Polytechnica Vol. 51 No. 3/2011 Fig. 2: Evaluation of the range of cutting surface quality based on perpendicularity or angularity by EN ISO 9013 [7] Fig. 3: Evaluation of the range of cutting surface quality based on the mean height of profile Rz by EN ISO 9013 [7] In our experiments, we made precise measure- ments based on the EN ISO 9013 standard. The measurements focused on finding the perpendicular- ity, because the angle of the laser beam used in the experiments was α =0◦. The perpendicularity value was determined according to the following equation: u = U P S − U N S (1) where: u – perpendicularity value, U P S – measured value on theupper side of the cutting surface, U N S – measured value on the lower side of the cutting sur- face. The experimental surface roughness measure- ments focused on finding all roughness parameters Ra, Rq and Rz. However, parameter Rz was of greatest importance for determining the surfacequal- ity. The measurement was supplemented by a Vick- ers microhardness measurement. This is not de- fined in EN ISO 9013 as a surface quality parameter. However, microhardness is a very important prop- erty of thermally cut materials because of its effects on the other processes, especially mechanical work- ing. 40 Acta Polytechnica Vol. 51 No. 3/2011 3 Description of the experiment The following materials were chosen for an exper- iment to determine the quality characteristics of material cutting using a CO2 laser with different structures, i.e. with different alloys: S355J2C+N, QStE380TM and S2355JR. The samples were cut with dimensions 40 × 40 mm, 6 mm in thickness. The samples were marked by laser engraving, and laser setting parameterswere allocated for each sam- ple. Each material was cut to six different parame- ters. Each sample was measured ten times, and the valuewasverifiedby theGrubbs test. Theevaluation was made on the basis of the measured results. The measurements focused on the quality of the cutting surface. 3.1 Quality parameter measurement procedure Surface roughness. The touch method was used for measuring the roughness parameters. A sharp point which moves on the surface of the measured object was used for finding the surface roughness value. Themeasurementsweremade usingMitutoyo Surftest SJ-301 mobile equipment. This is workshop equipment, but its parameters were convenient for the experiment. The test results can be displayed in several international standardsDIN, JIS, ISO,ANSI. Fig. 4: Mean profile height Rz by EN ISO 9013 [7] Measuring of precision. Each sample was cut with nominal dimension N D =40mm. The aimwas to find the material and cutting parameters that are able to cut out the most precise dimension. The cut- ting surfacewas divided into two parts—upper side (Ups) and lower side (Uns), because the start andrun surface of thematerial is unevenlymelted. Themea- surement was made on ten points along a cut, 1 mm from the top cut edge and 1mmfrom the bottom cut edge. Themeasurement principle is illustrated in Fi- gure 5. The measurement was performed using the 3D coordinate Rapid THOME ME 5008 measuring machine with high-precision measurement. Fig. 5: Principle of precision measurement Vickers microhardness. This test involves im- pressingan indentor (adiamondsquarepyramidwith top angle 136◦) into the test material. The samples were loaded by force F =200gf for a period t =20 s in the normal direction on the surface of the sample. Ten impressionsweremade on each sample along the bottom cut edge at a distance of 0.20 mm from the edge, and the average microhardness was calculated nearest to the heat affected zone. Vickersmicrohard- ness ismarkedas HVM, and is defined as force size F on impression surface S. The principle ofVickersmi- crohardness measurement is illustrated in Figure 6. Fig. 6: Principle of Vickers microhardness measurement 4 Experimental materials 4.1 S355J2C+N (1.0579+N) material normative EN 10025-2/04 This is analloyedconstruction steelwithgoodductil- ity. It is used for steel structures, welded structures and machining parts with high tensile yield strength and for longandplaneproducts thatarehot rolled. It is forweldeduse, screwedand riveted structureswith frequent cold shaping (blending, flanging, beading, profiling), static and dynamic stressed, for working at normal temperatures andat reduced temperatures to −20◦C. It is suitable for all welded operations. It is suitable for cold shaping, with marking C. The fi- nal condition of the supplies is normalization rolled, with marking +N. 41 Acta Polytechnica Vol. 51 No. 3/2011 Table 1: Chemical properties of S355J2C+N material Quality based on EN 10 204-3.1 U. S. Steel Kosice Chemical analysis of melting with number 58479 in % S355J2C+N Nb V Ni Mo Cu CEV Cr 0.04 0.003 0.01 0.002 0.03 0.414 0.03 C Mn Si P S Al 0.20 1.20 0.47 0.012 0.007 0.042 Table 2: Mechanical properties of material S355J2C+N Quality based on EN 10 204-3.1 U. S. Steel Kosice Mechanical properties Lower yield point Breaking strength Tensibility KV Re Rm A5 [MPa] [MPa] [%] [◦C] [J] S355J2C+N 414 554 28.0 −20 83 4.2 QStE 380 TM material normative SEW 092/90 This is a micro-alloyed, small grained, high-quality steel with a low content of carbon, suitable for cold shaping. It is used for long and plane productswhich are hot rolled, e.g.: strips, sheet metals, wide steel. Final condition of supplies: thermomechanical rolled is marked TM. Steel quality marking of class QStE with a triple number which expresses the minimum lower yield point value Re, which is measured in the normal direction in the direction of rolling. 4.3 S235JR material normative EN 10025-2/04 This is a non-alloyed high-quality construction steel. It is used for plane and long products hot rolled in thickness up to 250 mm with a certain peak load for +20◦C. This steel is not suitable for heat treatment, except in the case of products supplied with status +N. These products can be hot shaped or normal- ized after delivery. Normalization after removing the internal stress is allowed. This steel is suitable for screwed and riveted constructions. Welding prop- erty: this steel is suitable for welding. Table 3: Chemical properties of QStE380TM material Quality based on EN 10 204-3.1 U. S. Steel Kosice Chemical analysis of melting with number 53019 in % QStE380TM C Mn Si P S Al Nb V Ti 0.08 0.90 0.01 0.009 0.006 0.039 0.04 0.001 0.013 Table 4: Mechanical properties of QStE380TM material Quality based on EN 10 204-3.1 U. S. Steel Kosice Mechanical properties Lower yield point Breaking strength Tensibility KV Re Rm A5 [MPa] [MPa] [%] [◦C] [J] QStE380TM 482 540 29.0 −40 40 42 Acta Polytechnica Vol. 51 No. 3/2011 Table 5: Chemical properties of S235JR material Quality based on EN 10 204-2.2 U. S. Steel Kosice Chemical analysis of melting with number 53019 in % S235JR C Mn Si P S Al N V Ti 0.19 1.50 – 0.045 0.045 – 0.014 – – Table 6: Mechanical properties of S235JR material Quality based on EN 10 204-3.1 U. S. Steel Kosice Mechanical properties Lower yield point Breaking strength Tensibility KV Re Rm A5 [MPa] [MPa] [%] [◦C] [J] S235JR 276 439 31.5 20 40 Table 7: Group of all cutting parameters used in the experiment Index of cutting parameters Cutting speed Power Gas pressure Cutting gap Focal distance of lens Nozzle diameter Gas [m/min] [W] [bar] [mm] [mm] [mm] 1 2.8 3200 0.8 0.3 7.5 1 O2 2 2.6 2700 0.6 0.3 7.5 1 O2 3 2.2 2000 0.6 0.3 7.5 1 O2 4 2 1800 0.6 0.3 7.5 1 O2 5 3.2 3200 0.8 0.3 7.5 1 O2 6 2.5 3200 0.8 0.3 7.5 1 O2 5 Experimental results For the experiment, the samples were marked with letters of the alphabet and numerical indices to dif- ferentiate the materials and the cutting parameters. The materials were marked as follows: • S355J2C+N by letter “B” • QStE 380 TM by letter “C” • S235JR by letter “D” Each material was cut with six different cutting pa- rameters (in Table 7). The cutting parameters were marked with numerical indices “1, 2, 3, 4, 5, 6”, in- dicating changes in cutting speed, power and work- ing gas pressure. The samples with the best quality results were selected for further tests. The surface roughness results are shown in Figure 7, Vickers mi- crohardness (Figure 8) and precision of the cut sur- face to nominal distance (Figure 9). Figure 7 illustrates three basic surface roughness parameters Rz – average value of the five highest points and the five lowestpoints in thematerial; Rq – sum of the average values of the highest and lowest points on themeasured length; Ra –averageof all de- flections on the measured length. QStE 380TM ma- terial showedthebest surface roughness,with cutting parameters: cutting speed – 2.2 m · min−1, power – 2000 W, gas pressure – 0.6 bar. Fig. 7: Evaluation of surface roughness 43 Acta Polytechnica Vol. 51 No. 3/2011 Figure 8 presents average Vickers microhardness values. These values were measured along the heat- affected area to obtain the average microhardness value. Again, the best results were forQStE 380TM material, but the cutting parameters were changed to: cutting speed – 2.5 m · min−1, power – 3200 W, gas pressure – 0.8 bar. Fig. 8: Vickers microhardness evaluation Fig. 9: Evaluation of dimensional inaccuracy Figure 9 illustrates the relation of dimensional inaccuracy, i.e. the size of the deflection, on the nominal dimension. The start-up of the laser beam causes a change inmaterialmelting on the upper side (the melting on the upper side is greater than on the lower side). It is therefore very important tomeasure the divergence between the values on the upper side and on the lower side. The graph in Figure 9 shows that QStE 380 TM material again has the best pre- cision values. For the purposes of the experiment, the upper side and the lower side of an experimental sample were melted. This was due to the increased exothermic reaction of the alloyed elements. A cor- rection can be made by changing the cutting beam parameters. The cutting parameters for the highest- precision sample are: cutting speed – 2 m · min−1, power – 1800 W, gas pressure – 0.6 bar. 6 Conclusion Our experiment focused on finding the influence of materials with different content of alloy elements on the quality of the cut surface. The results of the test show that for cutting with a CO2 laser the best material is QStE 380 TM. This material has a low carbide and alloy element content. It had the best results for all measured quality parameters. The re- sults also show that in order to achieve the required cut quality it is necessary to correct the cutting laser parameters, which also influence the cut quality. It is important in the component production process to determine the necessary priorities. These priori- ties depend on the subsequent processing or on the practical use of the products. It is very important to design an optimization solution for achieving the required results with minimum operating costs. Our results can help companies to improve the efficiency and cost-effectiveness of their production. References [1] Maňková, I.: Progreśıvne technológie. Vienala Košice, 2000, 275 p. ISBN 80-7099-430-4. [2] Vasilko, K., Kmec, J.: Delenie materiálu. Data- press Prešov, 2003, 232 p. ISBN 80-7099-903-9. [3] Havrila, M.: Progreśıvne technológie. TU v Ko- šiciach, FVT so śıdlom v Prešove. Prešov, 2002, 105 p. ISBN 80-7099-891-1. [4] Rasa, J., Jindrova, R.: Nekonvenčńı technologie. In: MMSpektrum2006,7, p. 34. ISSN1212-2572. [5] Maščenik, J., Batešková, E., Haľko, J.: Change the structure of the material technology of thermal effects of drilling flowdrill. In: SBW 2009: Robotization and automation in weld- ing and other techniques: Slavonski Brod, 11.–13. 11. 2009. Mechanical Engineering Fac- ulty, 2009, p. 187–190. ISBN 978-953-6048-51-9. [6] Fečová, V., Barna, J., Litecká, J.: The using of 3D coordinate measuring machine into the con- trol system of components made in engineering. In: Journal of Engineering and Technology for 44 Acta Polytechnica Vol. 51 No. 3/2011 Young Scientists. Vol.1, Issue 1 (2010), p. 11–16. ISSN 1338-2349. [7] Standard EN ISO 9013:2002 Thermal cutting — Classification of thermal cuts — Geometrical product specification and quality tolerances. [8] Hatala,M.: Laser – nástroj budúcnosti. In: Stro- járstvo, 2008, Issue 4, [online]: http://www.strojarstvo.sk/docwww/SK/299/ 299.pdf Ing. Juliána Litecká Phone: +421 051 772 37 96 E-mail: juliana.litecka@tuke.sk Department of Technological Devices Faculty of Manufacturing Technologies with a seat in Prešov Technical University in Košice Štúrova 31, 08001 Prešov, Slovakia doc. Ing. Jarmila Fabianová, CSc. Phone: +421 051 772 37 96 E-mail: jarmila.fabianova@tuke.sk Department of Manufacturing Technologies Faculty of Manufacturing Technologies with a seat in Prešov Technical University in Košice Štúrova 31, 08001 Prešov, Slovakia prof. Ing. Slavko Pavlenko, CSc. Phone: +421 051 772 37 96 E-mail: slavko.pavlenko@tuke.sk Department of Technological Devices Faculty of Manufacturing Technologies with a seat in Prešov Technical University in Košice Štúrova 31, 08001 Prešov, Slovakia 45