How to optimize cutting path planning to improve processing efficiency when laser cutting complex shapes of iron laser cutting of products ?
Release Time : 2025-12-31
In modern metal manufacturing, laser cutting of products has become the preferred process for forming complex contours of iron products due to its advantages of high precision, high flexibility, and non-contact processing. However, when dealing with complex shapes containing numerous holes, cavities, sharp corners, or micro-features, such as automotive parts, chassis structures, and decorative components, unreasonable cutting path planning can easily lead to problems such as excessively long idle strokes, frequent starts and stops, and uneven heat accumulation. This not only reduces production efficiency but may also cause slag formation at the cut, deformation, or even failure to pierce. Therefore, scientifically optimizing the cutting path is key to improving the efficiency and quality of laser processing of iron products.
1. Intelligent Sequencing: Reducing Idle Strokes and Improving Continuity
Idle strokes are one of the main factors affecting efficiency. The primary strategy for optimizing the path is the "proximity principle" and "regional clustering." Through the intelligent sequencing algorithm built into the CAM software, the system can automatically group adjacent geometric features together and arrange the cutting sequence according to spatial proximity. For example, by first cutting all the small holes in a specific area and then processing the outer contour, the laser head can avoid repeated back-and-forth movement at both ends of the workpiece. For sheet metal parts with hundreds of holes, proper sequencing can reduce idle time by more than 30%, significantly improving equipment utilization.
2. Common Edge Cutting and Micro-Connection Technology: Reducing the Number of Piercings
Each piercing is not only time-consuming but also forms a weld bead at the starting point, affecting surface quality. Common edge cutting technology identifies the shared contour lines of adjacent parts or cavities, allowing laser cutting of products to complete both edges, saving time and reducing heat input. For multiple identical parts in nested layouts, a "bridging" or "micro-connection" design can be used—leaving a 0.2–0.5 mm uncut segment between contours to maintain the overall rigidity of the parts during cutting, preventing displacement caused by thermal deformation, and avoiding individual piercing. After cutting, the micro-connection can be easily knocked off or separated by subsequent punching.
3. Layered Cutting and Power-Speed Coordinated Control
Complex graphics often contain areas with different thickness requirements or precision levels. Laser cutting of products can employ a layered cutting strategy: In the roughing stage, high power and high speed are used to quickly remove most of the material; in the finishing stage, power is reduced and speed is slowed down to ensure sharp corners and smooth cuts. Especially when dealing with internal sharp corners, "corner compensation" or "corner deceleration" functions are introduced to avoid overheating or corner collapse due to inertia. Modern laser systems support dynamic parameter adjustment, adjusting the focal position, gas pressure, and pulse frequency in real time according to the path curvature, achieving "multi-quality in a single pass."
4. Nested Nesting and Continuous Closed-Loop Paths
In batch processing, reasonable nesting of sheet metal is a prerequisite for path optimization. Efficient nesting software can tightly arrange different parts, maximizing material utilization and generating a continuous, unidirectional cutting flow. The ideal path should form a closed loop or spiral trajectory as much as possible to reduce acceleration and deceleration losses caused by sudden changes in direction. For example, cutting layer by layer from the outer contour inwards, or covering the entire sheet along a zigzag path, ensures smooth and continuous laser head movement, avoiding the impact of sudden stops and starts on the servo system.
5. Simulation Verification and Adaptive Feedback
Advanced manufacturing systems can virtually simulate the entire cutting path before actual cutting, detecting potential collisions, overheating zones, or logical errors. Some high-end equipment also integrates online monitoring modules to collect real-time data on cutting sparks, plasma brightness, or auxiliary gas flow. If an anomaly is detected, the system immediately pauses and adjusts subsequent path parameters. This "prediction-execution-feedback" closed loop allows path planning to move from static presets to dynamic optimization.
Path optimization in laser cutting of products is far more than a simple "connect the dots" game; it's a systems engineering project integrating geometric analysis, thermodynamic control, and intelligent algorithms. Through intelligent sorting, common-edge cutting, layered strategies, continuous nesting, and real-time feedback, modern laser processing can improve the cutting efficiency of complex iron products by 30%–50% while maintaining high precision. In today's pursuit of intelligent manufacturing and green production, efficient path planning is not only a powerful tool for cost reduction and efficiency improvement but also a core support for achieving high-quality, low-energy, and flexible manufacturing.
1. Intelligent Sequencing: Reducing Idle Strokes and Improving Continuity
Idle strokes are one of the main factors affecting efficiency. The primary strategy for optimizing the path is the "proximity principle" and "regional clustering." Through the intelligent sequencing algorithm built into the CAM software, the system can automatically group adjacent geometric features together and arrange the cutting sequence according to spatial proximity. For example, by first cutting all the small holes in a specific area and then processing the outer contour, the laser head can avoid repeated back-and-forth movement at both ends of the workpiece. For sheet metal parts with hundreds of holes, proper sequencing can reduce idle time by more than 30%, significantly improving equipment utilization.
2. Common Edge Cutting and Micro-Connection Technology: Reducing the Number of Piercings
Each piercing is not only time-consuming but also forms a weld bead at the starting point, affecting surface quality. Common edge cutting technology identifies the shared contour lines of adjacent parts or cavities, allowing laser cutting of products to complete both edges, saving time and reducing heat input. For multiple identical parts in nested layouts, a "bridging" or "micro-connection" design can be used—leaving a 0.2–0.5 mm uncut segment between contours to maintain the overall rigidity of the parts during cutting, preventing displacement caused by thermal deformation, and avoiding individual piercing. After cutting, the micro-connection can be easily knocked off or separated by subsequent punching.
3. Layered Cutting and Power-Speed Coordinated Control
Complex graphics often contain areas with different thickness requirements or precision levels. Laser cutting of products can employ a layered cutting strategy: In the roughing stage, high power and high speed are used to quickly remove most of the material; in the finishing stage, power is reduced and speed is slowed down to ensure sharp corners and smooth cuts. Especially when dealing with internal sharp corners, "corner compensation" or "corner deceleration" functions are introduced to avoid overheating or corner collapse due to inertia. Modern laser systems support dynamic parameter adjustment, adjusting the focal position, gas pressure, and pulse frequency in real time according to the path curvature, achieving "multi-quality in a single pass."
4. Nested Nesting and Continuous Closed-Loop Paths
In batch processing, reasonable nesting of sheet metal is a prerequisite for path optimization. Efficient nesting software can tightly arrange different parts, maximizing material utilization and generating a continuous, unidirectional cutting flow. The ideal path should form a closed loop or spiral trajectory as much as possible to reduce acceleration and deceleration losses caused by sudden changes in direction. For example, cutting layer by layer from the outer contour inwards, or covering the entire sheet along a zigzag path, ensures smooth and continuous laser head movement, avoiding the impact of sudden stops and starts on the servo system.
5. Simulation Verification and Adaptive Feedback
Advanced manufacturing systems can virtually simulate the entire cutting path before actual cutting, detecting potential collisions, overheating zones, or logical errors. Some high-end equipment also integrates online monitoring modules to collect real-time data on cutting sparks, plasma brightness, or auxiliary gas flow. If an anomaly is detected, the system immediately pauses and adjusts subsequent path parameters. This "prediction-execution-feedback" closed loop allows path planning to move from static presets to dynamic optimization.
Path optimization in laser cutting of products is far more than a simple "connect the dots" game; it's a systems engineering project integrating geometric analysis, thermodynamic control, and intelligent algorithms. Through intelligent sorting, common-edge cutting, layered strategies, continuous nesting, and real-time feedback, modern laser processing can improve the cutting efficiency of complex iron products by 30%–50% while maintaining high precision. In today's pursuit of intelligent manufacturing and green production, efficient path planning is not only a powerful tool for cost reduction and efficiency improvement but also a core support for achieving high-quality, low-energy, and flexible manufacturing.