Robot based remote laser cutting of three-dimensional automotive composite parts with thicknesses up to 5mm

Abstract

With the intention to develop a robot based laser cutting process for automotive 3D parts with varying thickness consisting of carbon fibre reinforced plastics (CFRP), strategies of 2D investigations were adapted. The used setup consist of a fibre guided nanosecond pulsed laser with an average power of P L = 1.5 kW, a 6-axis robot and a 3D programmable focusing optic (I-PFO). In a first instance strategies for the remote cutting of material with a thickness of d = 5 mm were developed and optimized concerning cutting efficiency and quality. In a second step the results were transferred to a robot based 3D cutting process. Main challenges are the consideration of the correct angle of incidence, the geometric constancy and the accessibility of the cutting geometry by the I-PFO for complex shaped 3D parts. Therewith, “cutting-on-the-fly” strategies were realized for automated trimming and drilling of large automotive structures.