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LaserCUSING
Contents
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prepare the CAD data for the LaserCUSING component to be produced for the construction
process). The Magics software runs on a standard PC.
This software reference is intended for the operator and user of LaserCUSING machines.
It may also be used as the basis for training the appropriate personnel.
1.3 Storage
The software reference must be stored so that it is at hand at all times close to the M1 cusing
machine!
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2 Safety
2.1 Intended use
The Magics 3D software is used exclusively to prepare the CAD data for the LaserCUSING
component to be produced for the construction process.
Any other use or use which extends beyond this is deemed not to be intended. The person operating
or controlling the machine is responsible for all damage which is caused by non-intended use!
Intended use also includes:
reading this software reference and complying with all of the instructions contained within it, in
particular the safety instructions.
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Liability disclaimers:
CONCEPT Laser GmbH does not accept any liability for personal, material,
environmental and / or operational damage caused by the software reference
not being complied with or not being complied with in full.
If unauthorised alterations are made, the guarantee shall be cancelled.
Guarantee and liability claims for personal, material and environmental damage
shall be excluded if they can be attributed to one or more of the following
causes:
Please consult our general terms of delivery or your contract documents for
details of the guarantee.
the software is only used as intended (see Section 2.1 Intended use).
the software is only operated in perfect, working condition. If any errors are identified in
the software, or if safe operation cannot be guaranteed for other reasons, the
LaserCUSING machines may only be put back into operation after the errors have been
corrected.
You should also contact our customer service team if you notice any faults or defects
during operation or suspect that the software is not working properly.
the software reference is always available in a legible format and in full to the operating
personnel at the place where the LaserCUSING machine is used.
only suitably qualified and authorised personnel operate and maintain the software.
these personnel regularly receive instruction on all the relevant matters of industrial
safety, and also that they are aware of and follow this software reference and in particular
the safety instructions which it contains.
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Note:
This symbol indicates information which should particularly be noted or helps to improve
understanding.
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3 3D-Software Magics
The Magics 3D software is a data processing program. The components here first need to be read in
in 3D CAD format (file *.stl). After possible data record repair and construction of the support
(component support construction), the layer data (slices) are generated for the LaserCUSING
process.
This slice data record which is generated (file *.cls, CONCEPT Laser slice file) can now be transferred
to the ConceptLaser machine software (see Chapter 4 Part II ConceptLaser machine software).
X, Y and Z denote the spatial axes for the LaserCUSING components in the Magics 3D
software and the ConceptLaser machine software.
U, V and W denote the moving axes of the construction module.
Please see the Magics 3D software manual for further details.
After opening the Magics 3D software and reading in the STL part, this is displayed on the screen. The
position in the coordinates system is taken from the construction data.
Fig. 1:
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With the command Move to default position, the component is placed against the coordinate axis in
the positive range.
Fig. 2:
Move part(s)
The component is then aligned in accordance with the coordinate axes. In addition, a flat surface is
marked on the component with which it should stand on the construction plate command Bottom
surface/Top surface
Fig. 3:
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Fig. 4:
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Missing triangles
Fig. 5:
Missing triangle
Fig. 6:
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Fig. 7:
Transverse triangle
Fig. 8:
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Open edges
Open contours
Shells
Open edges or Open contours must display the value 0 after repair.
Shells means surfaces. For example, if the component is a solid ball, it has one surface. If the ball is
hollow, it has two surfaces. In our training example, the connecting rod has one surface, not five (see
Figure 8).
If the repair is not successful, individual triangles can be inverted, deleted or the
appropriate holes can be filled.
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Fig. 9:
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Then return the component to the Standard position and move upwards by an
appropriate amount in the Z direction in order to be able subsequently to release the
component from the construction plate (e.g. 0.5 mm for a wire-cutting machine).
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All surfaces at an angle of less than 45 to the construction plate must be supported!
Mark the surfaces.
Then cut off the component at the height of the construction plate (first in the Sections view, then
with the Cut
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The support construction now features a very thin web which in some circumstances may cause
problems during production.
This web can be enlarged again by 10 mm with an Extrude command.
After extrusion mark and delete the front side, cover surface and corresponding triangles of the side
area, and use the Gen. triangle (Generate triangle) and Fill holes function to close the surface.
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Use the Standard geometry function to generate a cylinder with a diameter of 8 mm, the same
length as the hole or slightly more (15 mm) and a tolerance of 0.01 mm.
Use the Arrange function to position the cylinder in the middle of the previously closed hole.
Remove the cylinder from the component with the Boolean function.
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Important:
Save the component under the name Pleuel_Sup.stl not under Pleuel.stl!
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Fig.18: Parameter menu of the ConceptLaser slicer with cusing standard parameters
Slice thickness
Beam compensation
Skin core
Additional contours
Islands
Layer thickness
Distance between the island structure and the original contour
Subdivision of the surfaces in the inner and outer area
Flush termination of the lasered contour with respect to the
component contour or allowance generation
Size of the exposure vectors.
(An island rotation of 45 avoids exposure vectors parallel to the
coater blades)
Important:
The subdivision into inner and outer surfaces may not be applied with cooling channel
parts as even powder application is then not guaranteed!
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b
beam compensation
border of the island structure
conture drive
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3.5.2 XY Offset
As smaller the parts are, as smaller the value can be. The maximum value should not be bigger than
0,3mm, the standard setting is 0.
3.5.3 Hatching
The setting 2 mm in X and Y has the best results. The right rotation angle is 45 degrees.
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3.5.5 Fragmentation
The adjustments for the fragmentation correspond to the hatching parameters. 2mm in X and Y create
small crosses. The gap between of these crosses is the separation width factor 0,3mm.
It is also possible to fragment the borderlines. If you combine both possibilities the separation width
factor should be smaller than <0,1mm.
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3.5.6 Perforation
The value for the beam varies between 0,7 and 0,9mm. This depends on the material. The height is
the start height for the perforation. These settings can be changed in the machine library (see later
point 8). The solid height is the distance between the perforation and the teeth to the part. Our
experience shows that 1mm is a secure value.
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high 2mm
top length 0,4mm
fragmentation 1,0mm
Alternatively the pillars could be minimised, so that the connection could be minimised too (hatching
0,7mm).
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3.6.2 Slicen
Slicing in Magics the additional contour inward has to set up to 50m.
M1cusing
Mlabcusing
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treatment
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gas
heating up
holding
cooling down
argon
400C/h
1150C, 1h
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2011
All rights are retained by CONCEPT Laser GmbH,
even in the event of property right applications. All
powers of disposal, such as copying and forwarding
rights, are retained by CONCEPT Laser GmbH.
Printed in Germany
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