Welding threaded bushings on curved sur-faces – all working steps in one process cell
Thanks to the innovative CutFusion method on our FLC series of machines, all the machining steps necessary for welding threaded bushings can be carried out in one process cell. The FLC combines technologies for laser cutting, part support for additional components and laser welding in one single machine.
The machine is loaded manually with unfinished parts and additional components, and manufactures parts in a typical cycle time of approx. 10 sec per threaded bushing using the two-station concept. Depending on the machining station and the part/jig size, up to three different parts can be manufactured in one clamping.
For more complex parts with several bushings facing in different directions, up to three NC axes can be integrated per station for turning the part in the clamping device.
The FLC combines technologies for laser cutting, component feeding for additional components and laser welding in one single machine. Thanks to the balancing of all optics axes and component feeding through the zero reference mark, the position for component feeding and welding contour is always given 100% after laser cutting and does not have to be determined using an additional measuring function. This results in a decisive advantage in terms of machining time as well as the resulting quality of the parts.
The FLC also combines further innovative technology such as a rotation optic and the 3D-WeldTracking method which has been developed especially for welding bushings.
Thanks to the rotation optic a higher contour track speed and acceleration can be achieved than with conventional B-C heads (minimum compensatory movements).
3D-WeldTracking always guarantees perfect weld connections even on components with higher unfinished part tolerances (e.g. hydroformed parts). During laser cutting, the actual part position is compared with the target part position, and a new contour is generated from the deviations for the downstream laser welding.
Further advantages compared with conventional production with MAG are due to costly part preparation (plateau stamping) no longer being necessary as well as better accessibility of the laser beam to the joint contour and significantly lower heat impact (less component deformation).
Typical problems with MAG welding such as soiling of the thread turns by weld splatter no longer occur at all. Cost- and space-intensive logistic applications such as those required for sequential manufacturing concepts are no longer required either.
Thus with the FLC you get a turnkey solution for manufacturing parts with laser-welded threaded bushings.
- All production steps in one machine & one fixture
- No punching process & no expensive toolings
- No costly part preparation required
- No expensive filler wire required as for MAG welding
- No missconnections as after MAG welding
- No weld spatters
- Low heat impact => almost no part deformation
- More flexibility when launching new products
- Increase of productivity (approx. 10 s / bushing)