As a country's main industry, shipbuilding industry occupies an extremely important position in the industrial composition of its country. Therefore, the improvement and development of shipbuilding technology cannot be ignored. According to the technological development in the past 55 years, a large number of products and manufacturing processes in the shipbuilding industry have been upgraded.
Among them, cutting is one of the most critical production technologies in the shipbuilding industry. In recent years, laser cutting technology has also been applied in the shipbuilding industry.
1). Application of cutting in shipyards In a typical shipyard, the production process starts with the marking steel plate, followed by cutting the hull and internal structure, and finally the overall construction of the ship. The plate printing system used for the marking process includes special machinery for printing the entire large steel plate at one time. Numerically controlled oxy-combustion cutters/plasma cutters and laser cutters, gate cutters and portable cutters are all used in the cutting process. Heating torches and portable welding machines will be used for the assembly/welding process, and Lugger knives (large structures for hooking off to be removed later) will be used for the final finishing process. In addition, there are marking/cutting machines for angle iron cutting or cutting holes.
Among all the equipment used in the shipbuilding industry, CO2 laser cutting machines enjoy a high reputation because they reduce labor, welding costs and time, and reduce secondary processing after cutting. Initially, people thought that laser cutting would be very difficult to use in the shipbuilding industry because the requirements for bevel cutting were many and complex. In the end, plasma cutting machines, manufacturing machines, and grinding machines are also used in many operations. Recently, this phenomenon has changed, because many different cutting procedures have been developed, with a laser bevel cutting torch and its own programming system. Laser groove cutting can achieve high precision, high added value, and can also reduce the subsequent production time and cost of cutting, such as in assembly and welding.
2) Advantages of laser cutting The laser cutting seam width is 1/8 of the plasma cutting, and the part size can tolerate a thermal deformation of +/- 1 mm maximum. In this way, the laser cutting part is more advantageous for subsequent assembly equipment and welding steps, reducing the debugging time and welding mistakes of the joints. In shipyards, single-sided sub-arc welding of copper backings with soldering fluxes is becoming more and more popular, and highly accurate Y-cutting dimensions are required during the welding process, which is difficult to accomplish with plasma Y chamfers.
All Koike laser cutters operate in a rail system. Therefore, they can cut large steel plates. The machine is also used to cut different steel plates in one processing step without changing the nozzle or the focusing lens, even if the plate thickness is not uniform. This feature allows the machine to run automatically for a long period of time, including night-time operations, and it is also stable and safe. When the machine can run automatically, labor costs are reduced compared to plasma cutting machines.
An important part of the laser cutting process is the quality of the metal, especially in cutting steel plates. The surface conditions are very important. When the steel plate is covered with black scale and rust, unstable cutting results will occur because the user should pay attention to avoid similar situations during the processing. Recently, high-strength steel plates have been used to reduce the weight of the final product; this also has an effect on the final cutting effect. Zinc-rich precoated panels are used in shipbuilding and the surface coating must be less than 20 microns. Excessively thick surface coatings can affect the quality of the cut. A 6 kW power CO2 laser cutter is used to cut straight 30 mm thick steel plates. Even so, manufacturers must understand that the material and steel conditions directly affect the cutting results.
3) Laser Bevel Cutting Due to the lack of skilled operators and high labor costs, shipyards are increasingly demanding laser bevel cutting. The shipyard will use a variety of different types of bevel cutting, such as V-cut, Y-cut bevels with varying edge plate widths, CVBA (continuously changing bevel angle) cuts, tube-hole cuts, 3mm hole-cutting, and construction cuts. Drain cutting. Koike is trying to study a variety of miter methods to reduce production time and mechanical startup time. Cutting software was also developed at the same time to prevent the parts from being subjected to overpressure. For example, bridge cutting is included in the automatic programming process because two cutting paths are required in the Y-slant cutting of the edge band plate. Koike created the ideal laser chamferer with automatic programming features. Many shipyards are pleased with this invention and have ordered multiple equipment.
4) The Future of Laser Cutting in Shipbuilding Applications According to the foregoing description, complex cutting shapes can be automated by simply pressing a button on a laser cutting machine. In the past, skilled operators were often required to complete the cutting pattern. As a result, the shipyard can reduce the number of workers without worrying about cutting shapes and subsequent welding processes. For multiple axis requirements, laser bevel cutting still requires unnecessary movement during piercing, such as at corners and during positioning. The plan for the future is to minimize similar and unnecessary movement to increase production efficiency.
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