When we talk about consumables, we’re referring to parts that wear out quickly, have a short lifespan, and need regular replacement, like nozzles, ceramic rings, and protective lenses. Understanding these consumables, their roles, and how to manage them efficiently is crucial for maintaining the performance and cost-effectiveness of your laser cutting operations.

1 Get to Know Consumables

1.1 Protective Lens

In metal processing, protective lenses play a crucial role in safeguarding the focusing lens group and collimating lens group from dust, spatter, and debris generated during cutting. Typically, fiber laser cutter is equipped with both upper and lower protective lenses, with the lower lens being more prone to contamination. If the protective lens is damaged, it can result in the laser head not emitting light, damage to the protective lens drawer, or even harm to the focusing lens.

How can you choose high-quality protective lenses? First, ensure the lens dimensions are compatible with your machine. Then, select the appropriate lens material and anti-reflective coating parameters based on your specific cutting environment and laser power. It’s recommended to choose lenses with excellent light transmission, high-pressure resistance, and precise craftsmanship for optimal performance and safety.

1.2 Ceramic Ring

The ceramic ring is essential for transmitting and collecting electrical signals from the laser head nozzle. It serves several purposes, such as effectively shielding the laser cutting head from impact and contamination, dissipating heat, and ensuring stable operation. If the ceramic ring is damaged, it can lead to instability in signal transmission, preventing accurate sensing of the distance between the cutting head and the metal sheet, increasing the risk of the cutting head colliding with the workpiece. When selecting a ceramic ring, it’s crucial to choose one with high sensitivity for stable signal transmission, as well as heat-resistant and high-temperature adhesive stability.

1.3 Nozzle

The nozzle, mounted on the cutting head, plays a crucial role in directing the flow of auxiliary gas. It fulfills various critical roles, such as controlling the focal position of the laser beam and preventing debris, like cutting melt, from bouncing back into the cutting head and damaging the focusing lens. When cutting different materials or thicknesses, it’s essential to select the appropriate nozzle diameter to maintain cutting quality. If the nozzle hole diameter is too large, molten material splashed during cutting can pass through the nozzle, potentially contaminating the lens. This increases the risk of lens damage, reduces lens protection, and shortens its lifespan. Therefore, choosing the correct nozzle size is critical for both cutting performance and equipment longevity.

1.4 Filters and Coolant

Filters and coolant are essential consumables for water chiller and laser source. Filters play a crucial role in removing impurities and controlling ion levels in the water tank, ensuring stable operation of the laser source. High-quality filters help reduce laser light attenuation and extend the lifespan of the laser source. Coolant is used to maintain the temperature of the laser source and cutting head, ensuring optimal performance and longevity of the equipment. Investing in top-grade filters and coolant can significantly enhance the efficiency and durability of your CNC fiber laser cutting machine.

1.5 Auxiliary Gas

Auxiliary gases are critical for laser cutter and are categorized into two main types. The first type includes cutting gases, such as clean, dry compressed air, high-purity oxygen, and high-purity nitrogen, which are supplied to the cutting head. The second type consists of auxiliary gases used for clamping in cylinders. When cutting different materials and thicknesses of metal sheets, it’s essential to choose the appropriate auxiliary gas. Oxygen is primarily used for cutting regular carbon steel; nitrogen is best suited for cutting stainless and alloy steels, while compressed air is ideal for cutting thin sheets where high-quality edge finish is less critical. It is crucial to adhere to the manufacturer’s specified purity levels to avoid equipment malfunction and potential safety hazards. Ensure that the gases are free from impurities such as water and oil, and continuously monitor gas pressure during operation to maintain optimal performance and safety.

1.6 Lubricants

Lubricants are used in the mechanical components to reduce friction and wear. Regular lubrication and replacement of lubricants are necessary to keep the machine operating smoothly and to extend the life of components such as gears, bearings, and linear guides.

2 Manage Consumable Costs

2.1 Perform Regular Maintenance

Regular maintenance checks help identify worn-out components early, preventing costly downtime and ensuring optimal machine performance.

2.2 Use High-Quality Consumables

While it may be tempting to use cheaper consumables, investing in high-quality consumables can extend the life of your machine and improve cutting quality, ultimately saving you money in the long run.

2.3 Optimize Machine Settings

Properly configuring your machine settings based on the material and cutting requirements can reduce the wear on consumables, extending their life and reducing replacement frequency.

2.4 Track Consumable Usage

Keeping track of your consumable usage can help you identify patterns and anticipate when replacements will be needed, allowing for better planning and cost management.

3 Maintenance Tips

3.1 Regular Cleaning

After extended use, sheet metal laser cutting machines can accumulate dust and dirt on components such as the cutting head, mirrors, and nozzles. To maintain optimal performance, it’s essential to clean these parts regularly. Use specialized cleaning agents and tools, and follow the manufacturer’s maintenance guidelines for best results.

3.2 Check the Lens and Nozzle

Lenses and nozzles are crucial components of laser cutter and should be regularly inspected for wear. If scratches are found on the lenses or if the nozzles are clogged, they should be cleaned or replaced promptly to ensure cutting quality.

3.3 Regular Replacement

Most consumable parts have a relatively short lifespan which varies depending on the material and thickness being cut. Before operating the equipment, it is crucial to inspect these components for any signs of wear and replace them promptly. The following table provides recommended usage durations for various consumables under normal operating conditions.

Regular monitoring and timely replacement are key to maintaining optimal performance and preventing unexpected downtime.

3.4 Coolant Replacement

For optimal performance, please use pure water, distilled water, or deionized water as coolant. In environments where temperatures drop below 0°C, the coolant may freeze and damage the laser source. To prevent this, antifreeze should be added. Regularly replacing the coolant is essential to maintain effective cooling and ensure the longevity of your equipment. 

3.5 Maintenance Log

Maintaining a detailed log of all maintenance activities is highly recommended. By recording each maintenance task and its date, users can better track the operational status of their equipment and promptly identify and address any issues. A well-maintained log helps ensure consistent performance and can prevent potential problems before they escalate. 

Conclusion

In the daily operation of a CNC fiber laser cutting machine, consumable wear is inevitable. Understanding their functions, proper usage, costs and maintenance can help you minimize equipment damage, boost production efficiency, and ensure a better overall experience with your machine.