LASERTEC

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Laser machining for manufacturing precision tools

Perfect tools with laser machining

LASERTEC 20 PrecisionTool

PH 10 | 100 linear magazine automation

LASERTEC 20 / 50 FineCutting

LASERTEC 50 Shape (Piko)

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Wherever conventional mechanical machining processes such as grinding and eroding are pushed to their limits by excessive process forces or negative thermal reactions in diamond cutting materials, innovative laser technology can bring its unique strengths and numerous advantages to bear. A pioneer in this field, SAUER has many years of experi-ence in lasering PCD, CVD-D, CBN and carbide. In particular, the LASERTEC 20 / 50 series covers the separation of PCD circular blanks and the creation of chip breakers and finishes on cutting edges as well as clearance angles. As the machines use a novel laser source with high energy efficiency and do not require any consumables, the diamond tool manufacturing technology can said to be green.

Laser machining for manufacturing precision tools

Perfect PCD cutting edges, rapid separation of circular blanks, carbide extrusion die with Ra = 0.3 μm.

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Perfect tools with laser machining

Applications

LASERTEC 20 PrecisionTool LASERTEC 20 / 50 FineCutting LASERTEC 50 Shape (Piko)

CUTTING EDGESwith clearance angle and hip breaker geometry in PCD / CVD-D

SEPARATIONof PCD / CBN cutting inserts from circular blanks

EXTRUSION DIEand prototype indexable inserts made of carbide

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In light of the consistent demand for PCD precision tools, many tool manufacturers are facing the major challenge of sustainably optimising their production process chains. The key pro-cess steps in this context are the segmentation of PCD elements and the subsequent finishing of the tools. In both cases, laser technology has emerged as the most efficient solution with the best machining results. It produces perfect cutting edges which extend the life span of PCD tools by up to 2.5 times compared to conventional manufacturing. The cutting edge radius that can be produced by laser technology is between 2 and 3 µm.

LASERTEC 20 PrecisionTool / FineCutting

The laser offers unique advantages compared to grinding and wire-cut EDM.

Laser vs grinding and eroding.

Grinding

+ The diamond grains break out

+ Coarse-grained PCD varieties cannot be ground

+ Chip breakers are not possible

+ Wear on the grinding disc limits the corner radius

Eroding

+ Diamond cannot be eroded, only the binding material

+ Coarse-grained PCD varieties cannot be eroded

+ Chip breakers are not possible

+ The wire diameter limits the corner radius

+ The eroding process has to be carried out 2-3 times for good quality

Lasering

+ Lasers work through diamond and the binding material

+ Coarse-grained PCD varieties can be processed easily

+ Chip breakers are possible

+ Minimum corner radius: 15 µm

+ Perfect cutting edge with no breakouts

10 µm 10 µm 10 µm

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Cutting edges with no breakouts, clearance angle and chip breakers made of PCD / CVD-D and CBN.

Highlights of laser machining PCD / CVD-D and CBN

1 Non-contact precision machining without tool wear

2 Cutting edge without breakouts since the laser cuts through diamond and binding material

3 High-quality machining even of coarse-grained PCD varieties

4 Chip breakers in the clamping area can be incorporated in one set-up with the cutting edge machining

5 Internal radii of at least 15 µm are possible

6 Low operating costs (no costs for wire-cutting or grinding)

7 Automation solutions for handling cutting inserts, end mills and Monoblock tools with HSK holders

8 LASERSOFT software packages for the laser machining of end mills, ISO and special cutting inserts and chip breakers – with a marking module

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The LASERTEC 20 combines dynamics, precision, compactness, diversity and intelligence in one high-tech machine. The linear drives in X / Y / Z with > 2 g, the 5-axis portal design with built-in NC swivelling rotary table on a compact footprint of just 3.5 m², maximum contour accuracy as well as the numerous application-specific LASERSOFT software features are merely most remarkable highlights of this high-precision machine. With its universal 5-axis kinematics featuring built-in A- and C-axes, the extremely stable monoBLOCK® design and its outstanding positioning accuracy and repeatability, the LASERTEC 20 is ideally suited to machining perfect cutting edges with clear-ance angles and / or PCD / CVD-D chip breaker geometry as well as the separation of PCD circular blanks with the highest standards of quality.

LASERTEC 20 PrecisionTool / FineCutting

Highly dynamic 5-axis precision machining on a footprint of just 3.5 m².

Highlights

+ Highly dynamic 5-axis precision machine with 5 µm positioning accuracy and portal configuration, on a compact footprint of just 3.5 m²

+ Unrivalled dynamics with linear drives in the X-, Y- and Z-axes with > 2 g

+ Integrated swivelling rotary table (4th / 5th axis as standard) with torque technology (–15° / +130°)

+ Precision cooling in all axes

+ Maximum workpiece size: ø 200 mm × 344 mm (may be limited by the position of the C-axis)

+ SINUMERIK 840D solutionline 3D contouring system with user-friendly CELOS® interface

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1: Clearly structured, extremely compact, optimally accessible working area with integrated NC swivelling rotary table 2: Highly compact, fully integrated PH 10 | 100 linear magazine for handling cutting inserts, end mills and HSK tools

Retusche3 Long-term stability

Stable, vibration-dampening mineral composite column (approx. 3 t) in our monoBLOCK® design – on a compact footprint of just 3.5 m²

4 Linear technology

Linear drives with > 2 g max. acceleration and precision cooling in X / Y / Z as standard (60-month warranty)

5 3D workpiece measurement

High-precision tool measurement and workpiece positioning in the working area with the infra-red measuring sensor

6 Zero-point clamping system

High-repeatability workpiece handling e.g. via the HSK interface

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Linear magazine PH 10 | 100

Ultra-compact handling system with application- specific configuration levels.

+ Ultra-compact linear magazine with optimum accessibility and with workpiece automation from above

+ Automation solutions for handling cutting inserts, end mills, tools with HSK interface (different types of tools can be combined)

+ Application-specific configuration levels for handling a maximum of 42 HSK tools

+ Option: Replaceable gripper hands on the handling arm for HSK tools, shank tools or cutting inserts

+ Tool clamping using collet system or hydraulic expansion chuck

LASERTEC 20 PrecisionTool with PH 10 I 100 linear magazine

1: Exchange of HSK tools via an HSK63 holder or of shank tools via a hydraulic expansion chuck 2: Handling of cutting inserts, end mills and HSK tools 3: Option: Fixed storage for pallets, cutting inserts or shaft tools

Max. number of levels 6* / 4** 6* / 4**

Number of places per level 7 4

Raster dimension (centre of pallet to centre of pallet) 95 mm 190 mm

Maximum tool diameter 85 mm 140 mm

Max. tool length (from HSK face contact) 240 mm 240 mm

* Max. tool length 135 mm, ** Max. tool length 240 mm

All in one:Laser machining of a cutting edge, clearance angle and chip breaker geometry in a PCD progressive die on the LASERTEC 20 PrecisionTool

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Machine set-up

+ Long-term stability: mineral cast base frame

+ Dynamics: The latest linear /torque technology

+ Precision: Positioning accuracy on the µm scale

+ Versatility: 5-axis version to pre-cut clearance angles

Technology

+ Clean, precise cuts

+ Conicity at 3.2 mm Material thickness only 25 µm per side

+ Low heat-affected zone from 50 μm

+ Clearance angle cutting speeds of up to 100 mm/min. in 1.6 mm PCD

LASERTEC 20 / 50 FineCutting

Highly dynamic separation of PCD / CBN circular blanks is 10 × faster than wire-cut EDM.

1 – 4: Separation and cutting-out of PCD and CBN circular blanks in 2D and 3D, 10 × faster than wire-cut EDM

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LASERTEC 50 Shape (Piko)

3D laser removal with pico-second laser for manufacturing carbide extrusion dies with Ra = 0.3 µm.

Thanks to its highly compact, stable design, in combination with the high-performance pico-second laser the LASERTEC 50 is particularly suited to demanding 5-axis machining work involving the production of complex prototypes and special cemented carbide workpieces.

Indexable inserts –

Carbide prototypes

+ Automatic fine positioning

+ Simple programming based on 3D CAD data

+ Job Manager

Carbide extrusion die

with Ra = 0.3 μm

+ Picosecond laser with 25 or 50 W output

+ A high-end solution delivering the best possible surface quality

5-axis machining with

picosecond laser

+ Built-in NC swivelling rotary table for complex prototypes and special machining

+ High-repeatability workpiece handling, e.g. via the HSK interface

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1,41

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3,31

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2,81

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2,43

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2,03

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2,42

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2,03

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1,41

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1,39

0 2,00

0 2,39

0 2,77

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4,31

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3,10

070

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655

350

1,150 1,840

3,879

950 2.729

710

ExtractionFineCutting

ExtractionPrecisionTool

2.59

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1.88

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655

950

509

705

860

2,875

2,812

LASERTEC series

Layout plansLASERTEC 20 LASERTEC 20

Front view Top view

LASERTEC 20 with PH 10 I 100 linear magazine LASERTEC 20 with PH 10 I 100 linear magazine

Side view Top view

LASERTEC 50 LASERTEC 50

Side view Top view

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LASERTEC series

Technical dataAvailable as LASERTEC 20 PrecisionTool / FineCutting

Working area

X-axis mm 200

Y-axis mm 400

Z-axis (focusing axis) mm 280

Table size (3 axes) mm –

Maximum table load (3 axes) kg –

A-axis (swivel range) degrees –10 to +130

C-axis (turning range / speed) degrees / rpm 360° / 150

Table size (5 axes) mm ø 200

Maximum table load (5 axes) kg 10

Travel speed

Rapid traverse X / Y / Z m/min 40 / 40 / 40

Acceleration g > 2

Connected values and aggregates

Connected load (including aggregates) kVA max. 40

Operating voltage V/Hz 400 / 50

Machine / system weight kg 3,750

Machine dimensions W / D / H mm 2,200 / 2,020 / 2,200

Extraction system dimensions, W / D / H mm 340 / 660 / 1,400

Footprint, W / D / H mm 2,568 / 2,462 / 2,383

Control system

CNC control system CELOS® with SIEMENS 840D solutionline

Available as LASERTEC 50 Shape

Working area

X-axis mm 500

Y-axis mm 500

Z-axis (focusing axis) mm 700

Table size (3 axes) mm 400 × 500 (work surface)

Maximum table load (3 axes) kg 150

A- / B-axis (swivel range) degrees –100 to +160

C-axis (turning range) degrees 360° infinite

Table size (5 axes) mm ø 200

Maximum table load (5 axes) kg 14

Travel speed

Rapid traverse X / Y / Z m/min 60 / 60 / 30

Acceleration g 1

Machine / system weight kg 5,000

Footprint, W / D / H mm 3,700 / 4,250 / 2,400

Control system

CNC control system CELOS® with SIEMENS 840D solutionline