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DURMA Lasers

HD‐F & HD‐FL

Fly optic Fiber Laser

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DURMA and Durmazlar

Laser Plant Başköy Plant

Ataevler Plant

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Durmazlar machinery, founded in 1956, was the first sheet metal working machines manufacturer in Turkey.

The first production of Durmazlar was a manual sheet cutting machine. Nowadays Durmazlar is proudly offering a wide range of products in sheet metal working industry.

Durmazlar with its annually 6000 machine production capacity in its 150.000 square meter area, is the biggest sheet metal working machine producer company worldwide.

Durmazlar is offering its products with the brand name DURMA. Main technologies offered in Durmazlar are as follows

‐Laser cutting technology

‐Punch and forming technology

‐Plasma cutting technology

‐Bending technology

‐Cutting technology

‐Combined shearing technology

‐Programming systems

‐Automation technology

Durmazlar is working and continuously investing for its employee and production in order to achieve better success, better technology and better environment with its 1000 employee,. The company is aiming to be effective on its customer’s future improvements and to share big ideas by offering the latest technologies under the most competitive circumstances and forecasting their future requirements.

DURMA is world class brand name which is serving the world technology to its customers in 82 countries and growing together with them.

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A‐ DURMA FIBER MACHINE MODELS AND PARAMETERS

AXIS HD‐F 3015 – HD‐FL 3015 HD‐F 4020 – HD‐FL 4020 HD‐F 6020 – HD‐FL 6020 HD‐FX 3015

X mm 3000 4000 6000 3000

Y mm 1500 2000 2000 1500

Z mm 150 150 135 150

HD‐F 3015 – 4020 ‐6020 (Rack & Pinion)

HD‐FL 3015 – 4020 ‐6020 (Linear Motion)

HD‐FX 3015 (Rack & Pinion)

Speed X m/min 90 200 90

Speed Y m/min 100 200 100

Speed Combined m/min 130 280 130

Acceleration m/s2 12 20 12

Accuracy ± mm 0,05 0,05 0,05

Repeatability ± mm 0,03 0,03 0,03

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B‐ FIBER LASER TECHNOLOGY

Laser Source

The dynamic operating range of IPG’s low‐order‐mode kilowatt class fiber lasers is available from 10% to full power with no change in beam divergence or beam profile throughout the entire range. This allows a single laser to be utilized for both high and low‐power applications.

IPG lasers’ divergence specifications are far superior than other lasers and allow the use of long focal lenght processing lenses for vastly improved depth of field, less damage to optical components.

The units can be supplied with fiber lenghts to 100 meters, different fiber diameters. Fiber lasers have a monolithic, entirely solid state, fiber‐to‐fiber design that does not require mirrors or optics to align or adjust and are typically smaller and lighter in weight than traditional lasers, saving valuable flor space.

• Excellent beam parameter product • Constant beam power over entire power range • Small focus over large working distance • Maintenance free operation • Modular ‘Plug & Play’ design • Compact, Rugged & Easy to install • Estimated diode lifetime up to 100,000 hours

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C‐ BENEFITS OF FIBER LASERS

• High Beam Quality

• High Output Power

• Beam Delivery by Fiber

• No Mechanical Resonator

• No Serviceable Parts

• No Pumps, Filter, Mirrors, Tubes

• Time Sharing / Energy Sharing

• Mobile Laser • Low energy costs

• Accurate and fast cuts

• Cartridge System of Power Source

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D‐ CUTTING PERFORMANCES

1kw YLS 1000 2kw YLS 2000 3kw YLS 3000 4kw YLS 4000

Mild Steel(mm) 6 12 15 20

Stainless Steel(mm) 3 5 8 10

Aluminum(mm) 2 4 6 8

• Power the beam quality is the most important parameter of laser sources. • 1 kW fiber laser cuts as fast as 3kW CO2 in the range of 1-3mm stainless steel • The operating wavelength of around 1µm gives at room temperature about 2 times higher absorption in metals as

10,6µm. • Smaller focus diameter with better power beam quality called BPP • Low Focus Shift • Low losses in fiber cable • Smaller focus can produce higher power density or longer focus length, which makes the process more stable

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E‐ DURMA FIBER LASER MACHINES AND FEATURES 1‐ MOTION SYSTEMS

A‐ RACK & PINION SYSTEM HD‐F

• Low backlash planetary gear head

• Helical rack & pinion for smooth and silent motion

• Maximum compact precision (± 0,05mm positioning accuracy)

• High acceleration results ( 12 m/s2 )

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B‐ LINEAR MOTION SYSTEM HD‐FL

• No requirement of maintenance and lubrication

• Load is directly connected to the motor therefore there is no backlash or mechanical wear

• Higher level of accuracy (± 0,03mm)

• Premium acceleration results ( 20 m/s2 )

• Higher dynamic response by extensive avoidance of the effects of elasticity, play and friction as well as natural oscillation in the drive train

• Low thermal expansion

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2‐ AUTOMATIC DOUBLE PALLET CHANGER(SHUTTLE TABLE)

• The double pallet changer is designed to increase the productivity and minimize the material preparation time. The pallet changer allows loading of raw material sheets or unloading of finished parts onto one pallet while the other pallet on duty.

• It consists of an additional loading / unloading station with a second pallet, which enables the automatic exchange of the sheet metal in the work area.

1- Initial Position 5- Bottom table inside

2- Top table inside 6- Both Tables Outside

3- Top table outside 7- Both tables down to initial position

4- Both tables lifted

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3‐ SCRAP CONVEYOR

• Accessing to the parts without entering to the machine

• Improves productivity and cleanliness

• Minimize heat effect after cutting

4‐ FUME EXTRACTION SYSTEM

• Efficient fume extraction by means of shutters which are controlled in accordance with the axes’ position

• As a result filter is used efficiently

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5‐ CHILLER

• Laser source ( Slabs), the cutting head are cooled by chiller

• Water temperature stability for stable laser and best cutting quality

• Long consumable lifetime (lens, nozzle)

• Energy saving system

• Low noise fan

• 140 lt pure water capacity

• Working availability for large temperature differences

• Accuracy of IPG chiller for laser cooling +/‐ 1.0°C and for optic cooling +/‐ 0.5°C

6‐ FILTER • Used for the collection of dust, particles and fume generated during cutting

• Increased airflow by oval cartridge filters

• Nanofiber Ultraweb Media to filter more efficiently than filters with standard cellulose/polyester blend media

• Self cleaning • DF PRO 4 ( 3000m3/h) or DF PRO 6 (4500m3/h) models can be used according to sizes of machines

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7‐ CONTROL UNIT

• Web based interface Windows XP for an easy use

• Easy data entry using Durma interface , the operator can easily and quickly improve the cutting quality for different types of materials

• Look ahead function

• 40 GB program memory

• Ethernet connection

• Worldwide Siemens support

• 15” LCD flat screen

• G‐CODE programming language

• Machine quickly restarts from cutting interruption point, after power loss

• Advanced corner applications with power modulation provides perfect corners and soft cutting

• Remote diagnostic and service ability from a Durma location

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8‐ OFFLINE SW

The program can be completely created off‐line, using the CAD/CAM system Metalix or Lantek.

• The geometry of the piece to be cut can be directly drawn or imported from other CAD systems (in DXF or IGES etc).

• A data base makes the management of the technological table extremely easy, (offline software classifies parts sizes)

• Auto‐nesting allows the optimization of the material, by automatically defining the lay‐out of the figures to be cut which exploits the sheet metal to the maximum.

• Full‐automatic cutting. (Any CAD drawings can be imported to create NC Codes which are loaded to the controller via network or memory stick).Initiation of the program by pushing start button only.

• Common Cut‐common border of parts reduces cycle times and material disposals by cutting once

• Sprint Cut‐ chooses the shortest path of head from one to another contour

• Fast Head Path Collision Protection??

• Real font styles are supported to cut or mark

• Pre‐piercing finishes all piercings prior to contours

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10‐ LASER CUTTING HEAD

1‐ 2D LASER CUTTING HEAD

• Precitec Manual focus cutting head is used as standard and automatic focus head as an option.

• Capacitive sensor on the cutting head warrants the focal position and keeps the distance fixed on the working material.

2‐ 3D LASER BEVEL CUTTING HEAD

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11‐ FIBER LASER GENERAL VIEW

A ELECTRICAL PANELB FILTER C LASER SOURCED CONTROL PANELE SCRAP CONVEYORF MAIN FRAMEG LASER COVERSH SHUTTLE TABLEI CUTTING GASSES

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TOP VIEW

SIDE VIEW

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F‐ FIBER LASER WORKING CRITERIA

• Laser light moves from resonator to cutting head with fiber cables. • No mirrors used. • No back reflection on Cupper and Brass. • For 1‐3mm thickness high speed cutting. • No maintenence.

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• To choose correct machine type there is chart when thickness and material type ratio is given.

• Fiber laser can be focused to a spot size of 1/10th the diameter of the CO2-laser

05

10152025MS (O2)

MS (N2)

SSAlMg3

Copper/BrassDC040 (Max)

YLS2000 (Max)

Fiber

CO2

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G‐ DURMA FIBER LASER AVARAGE ENERGY CONSUMPTIONS ( KW / HOUR )

Because of different working technology fiber lasers have much more less electric consumptions than CO2 lasers.

Efficiency of CO2 lasers are %10 besides fiber lasers efficiency is %30. On CO2 Lasers for 1kW ouput power you will need 10kW elektric energy for system. Besides for fiber laser it is only 3.2kW. Results given below are maximum powers and for real time working is will be around %30 less than max. values.

TYPE POWER SOURCE MACHINE + CHILLER + FILTER(Kw) RESENATOR(kW) TOTAL(kW)

HD‐F

L

3015 2 Kw 38 6,4 44,4 3 Kw 38 10 48 4 Kw 38 15 53

4020 2 Kw 41 6,4 47,4 3 Kw 41 10 51 4 Kw 41 15 56

6020 2 Kw 43 6,4 49,4 3 Kw 43 10 53 4 Kw 43 15 58

TYPE POWER SOURCE MACHINE + CHILLER + FILTER(Kw) RESENATOR(kW) TOTAL(kW)

HD‐F

3015 2 Kw 18 6,4 24,4 3 Kw 18 10 28 4 Kw 18 15 33

4020 2 Kw 21 6,4 27,4 3 Kw 21 10 31 4 Kw 21 15 36

6020 2 Kw 23 6,4 29,4 3 Kw 23 10 33 4 Kw 23 15 38

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4 kW Fiber laser has at nominal operation energy consumption of 18kW instead of 60, 8 kW with 4kW CO2. By using heat exchangers in fiber lasers instead of compressor chillers the power consumption can be reduced furthermore.

• Fiber Laser is 42, 8 kW less consumption the electricity in an hour. 1kw/h =0, 06€, If the machine operates 5000h/year Fiber Electricity consumption is 12.850€ less yearly.

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Energy cost of 4kW Fiber Laser at nominal power is less than the standby costs of CO2‐Laser (4kW). The efficiency of fiber laser corresponds to the requirements for „Green Laser Power“. An efficiency of > 30% is usual for the advanced IPG‐Fiber laser technology.

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I‐ TOTAL COST OF OPERATION Savings in 3 years (5000 h / year): Electricity : 12.850€ x 3 Years = 38.550€ Consumable : 6.000€ x 3 Years = 18.000€ TOTAL COST ADV : = 56.550€

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J‐CUTTING RESULTS

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K‐ SPECIAL APPLICATIONS FOR FIBER TECHNOLOGY

Fiber lasers performs on various lengths. With advantage of cable technology for longer or complicated applications are possible and performs succesfully. Some applications of special variants of cutting.

SINGLE PIECE LONG CUTTING TABLES 12000X2000MM TABLE SIZE

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L‐ PIPE CUTTING APPLICATIONS

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Technical Specifications

Cutting length mm Depending on machine dimension

Max 3000/Max 4000/Max 6000

Max pipe loading Kg/m 120

Laser power source Rofin/IPG 2‐5 KW

Working diameter Min / Max Ø50 / Ø250

Max pipe thickness mm Up to 10 mm depending on laser power

Tube profile cutting Max 150x150 mm

Maximum positioning speed X / Y m/min 100

Maximum cutting speed m /min. up to 15 m/min depending on power and thickness

Positioning accuracy mm +/‐0.1

Repeatability mm 0.1

Mterials Mild steel/Stainless steel/Aluminum

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Pipe and tube profile rotation system;

- Pipe and tube profile rotation system. - Pipe diameter capacity of Ø50 up to Ø250 - Tube profile capacity of 150x150. - Fume extraction connection. - Adjustable support units for pipe and tube profile.

SOME SAMPLES

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M‐ HD‐FX 3015 Fiber Laser Consept

This model is produced for specific jobs for mainly thin materials and job shops which are producing parts for small quantities and several different types. It has nice advantage because of price / productivity with high dynamics and automatic pallet movement.

High dynamics (130m/min) Easy loading/unloading

Fast automatic table movement is standard With optional pallet changer

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N‐ DURMA COMPACT LOADING‐UNLOADING

Durma Loading & Unloading system provides fast material handling and same time takes less space and productivity.

System takes material from stock area or pallette with suction pads and moves to shuttle table of the laser system

Laser Shuttle Table

Sheet Stock Table

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GRIPPER GROUP Only vacuum table moves down not forks

Materials after cutting taken by forks onto palette

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O‐ DURMA TEST AND QUALITY TEST FOR FIBER LASERS

At the quality department a 3D measuring device is available. This can be used to set up a final quality and accuracy inspection for the machines before the

delivery. A proposed concept procedure is explained in what follows.

Procedure A standard measurement part is cut in a fixed material type and thickness under well defined conditions and always with the same NC program, so the entire sequence is fixed.

The part dimension should be as big as possible, but making the procedure ofcourse easy to handle. For example: 2m x 1m. İn the part, various holes are cut and their measurement can characterize different aspects of the accuracy and quality of the machine.

For example:

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• The black circle is the reference. It’s center location defines the zero‐point of the other measurements.

• The red circles center location is used to check the straightness of X‐axis and Y‐axis and can allow a precise calculation of the angle between X and Y.

• The yellow circles are made when both X‐ and Y‐ axis are driven. The location of these holes determines the overal positioning accuracy.

• The green holes are along Y‐axis and the center location determines the Y‐axis accuracy.

• The light blue holes are along Y‐axis and the center location determines the Y‐axis accuracy.

• The purple holes are measured to calculate the diameter. This will define the dynamic accuracy of the machine.

• The dark blue holes are measured to calculate the form deviation from a circle. This allows a further characterization of the dynamic and shape accracy of the machine.

Practical aspects

The procedure should be discussed with the people who operate the 3D measuring machine, so optimal hole sizes can be used to allow an accurate quality check and calibration of the laser machines. Similar procedure can be worked out for punching machines.

Specifications and tolerances for the different measurements must be clearly defined, so we can develop a true internal quality procedure as part of the final testing of the machines. When the procedure is well documented, it can be supplied to customers under special request.

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P‐ DURMA PRE‐INSTALLATION CHECK ‐ LIST

This document contains points which need to be taken into account by the customer before installing a Durma laser cutting machine. The customer should formally agree that he accepts and understands the pre‐installation requirements as part of the delivery.

Operating conditions

The Durma laser cutting machine should be installed in a dry and dust‐free environment with stable temperature. There should not be any equipment or machinery nearby that generates vibrations.

The ambient conditions should fulfill the following requirements:

Ambient temperature 10°C...35°C Ambient relative humidity 20%...75%

Recommended foundation

Durma recommends a floor foundation for the fixation area of the machine according:

Concrete strength class C30/37 Concrete slab thickness 500mm

Floor flatness in the machine area <10mm

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Electrical connection

The connection of the machine to the power supply of the factory is customer’s responsability. The requirements for the electrical power supply are:

Supply voltage 3 x 400V and PE Frequency 50Hz

Max. voltage fluctuation +/‐ 7% Trip characteristics of the fuse slow

Max. grounding resistance 4Ω

Compressed air connection

The connection of the machine to the compressed air supply is customer’s responsability. The requirements of the compressed air supply are:

Compressed air supply pressure 6bar...8bar Max. size of solid particles 5µm

Max. concentration of dust particles 5mg/m3

Max. dew point temperature +3°C Max. oil content 1mg/m3

Note that the air‐intake of the compressor should be from outside and not in the vicinity of any source of solvents or any other air pollution.

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Compressed air as assist gas

İn case compressed air is used as assist gas for the laser cutting process, the air quality requirements are:

Compressed air supply pressure 6bar...12bar Max. size of solid particles 0.1µm

Max. concentration of dust particles 0.1mg/m3

Max. dew point temperature ‐40°C Max. oil content 0.01mg/m3

Note that the cutting results with air as assist gas will depend a lot on the air qualiıty, on the maximum air pressure and on the air flow rate that can be maintained through the delivery system!

Assist gas connection

The connection of the machine to the assist gas supply is customer’s responsability. The requirements for the assist gas supply are:

Min. purity of O2 99.95% İnlet pressure of O2 6bar...8bar Max. flow rate of O2 500Nl/min

Min. purity of N2 99.95% İnlet pressure of N2 28bar...30bar Max. flow rate of N2 1500Nl/min

Note that the gas delivery system (regulators and gas tubing) should be dimensioned according the given inlet pressures and required flow rates! The longer the gas lines to the machine, the bigger the tubing diameters should be. Durma recommends the use of stainless steel gas lines with compression ring fittings.

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Cooling water

The demineralized water for the chiller delivered with the machine must fulfill the following requirements:

pH‐factor 6.5...7.5 Max. conductivity 10µS/cm

Dust collector

The filtered air from the exhaust of the dust collector delivered with the laser cutting machine should not be blown back into the factory hall. Durma recommends to use a Ø250mm steel tube to connect the clean air exhaust of the dust collector to the outside of the factory. The exhaust duct‐work should be as short and straight as possible and is customer’s responsability.