Optimizing Edge Rounding on Laser-Cut Sheet Metal Using the DM1100 C

 The DM1100C Edge Rounding Machine was recently tested to achieve an edge rounding radius of 0.3-0.5mm on stainless steel parts for a customer specializing in precision sheet metal fabrication and enclosures, particularly for laser-cut components that require precise edge rounding for improved handling and coating adhesion. The primary requirement was to obtain a uniform edge rounding while maintaining the integrity of the parts, which typically do not have burrs, making a Deburring Contact Roller or abrasive belt station unnecessary. Due to the high precision of modern fiber laser-cutting machines, burr formation is minimal, eliminating the need for additional heavy-duty deburring processes, as the laser-cut edges are already clean and sharp, requiring only edge rounding to ensure smoothness.

Testing Parameters and Process

The customer specializes in high-precision laser cutting and sheet metal processing, producing components for industries such as electronics, industrial equipment, and mechanical assemblies. Their operations require smooth edge rounding to ensure compatibility with downstream processes like bending, welding, and assembly., requiring precise edge rounding to improve handling and surface treatment results. Ensuring smooth and uniform edges is crucial for avoiding sharp edges in assembly processes and enhancing coating adhesion.

The samples were categorized into two groups:

1. Samples A to D: Maintained the same process conditions while varying pressure and speed.
2. Samples E, F, and G: Also followed a standardized set of conditions, focusing on different material interactions.~

Sample A after tests

Sample G after tests

To optimize edge rounding on laser-cut precision components used in enclosures, brackets, and structural elements, two different crossbelt consumable types were tested:

• Green Flex: A flexible mix of 40/60G abrasive + green fleece, designed for a more controlled material removal and edge rounding process.
• Violet Plus: A 3-row cut design with 60G ceramic + purple fleece, known for its efficiency in edge rounding applications.

Green Flex Block

Violet Plus Block

The tests were conducted at speeds between 1 m/min and 3.2 m/min to evaluate the impact of different throughput speeds on edge rounding efficiency.

Results and Best Performances

From the test results, samples B and F produced the most consistent and high-quality edge rounding:

• Sample B (Green Flex): The reduced feed speed combined with increased pressure resulted in superior edge rounding, surpassing previous tests in uniformity and smoothness.
• Sample F (Violet Plus): With one pass and a lower feed speed than the previous sample, this test provided the best overall combination of edge rounding and surface quality.

Sample B: edge rounding detail

Sample F: edge rounding detail

Choice of Consumables: Why Violet Plus?

When processing thicker parts, Green Flex is ideal as it allows for higher pressure applications, such as 3.7mm of pressure, effectively reaching below the surface without affecting the integrity of the part.

For thinner parts (2mm thickness), applying excessive pressure (e.g., 1.5mm) could risk contact with the conveyor belt, potentially damaging it and leading to a suboptimal rounding result.

By utilizing Violet Plus, which contains harder abrasives, we were able to reduce the pressure to just 0.5mm while still achieving a similar edge rounding effect to that of Green Flex.\

Throughput Speed Selection: Why 1 m/min?

• We tested speeds between 1 m/min and 3.2 m/min to determine the best balance between efficiency and edge rounding quality.
• Higher speeds resulted in less uniform rounding, leading to inconsistent edges.
• 1 m/min provided the most uniform and consistent rounding, ensuring a smooth and controlled finish.

The DM1100C Edge Rounding Machine successfully delivered a 0.3-0.5mm edge rounding with a high degree of consistency, meeting the customer’s expectations for laser-cut sheet metal components that require precise edge refinement for handling and further processing. However, the DM1100 C only features top crossbelt processing, meaning edge rounding is applied from above, but not on the underside of the part.

For an optimized and more efficient solution, the DM1600 2C EVO is recommended. This model features two crossbelt stations, allowing for simultaneous top and bottom edge rounding, ensuring a fully uniform finish on both surfaces. With a wider 1600mm working capacity, it can handle larger parts while maintaining the same precision and efficiency.

This edge rounding system is particularly effective for manufacturing applications, where sharp edges must be smoothed to meet functional and aesthetic requirements in industries such as aerospace, medical technology, and custom metal fabrication., ensuring optimal surface preparation for powder coating, anodizing, and other protective coatings, improving adhesion and corrosion resistance. Many industries, including precision sheet metal fabrication, electronics enclosures, and industrial equipment manufacturers, rely on crossbelt edge rounding technology to achieve high-quality radiused edges, essential for safe handling, improved assembly fit, and superior coating performance.

These results confirm the effectiveness of the DM1100 C in post-laser-cut processing, ensuring consistent edge preparation for parts used in automated assembly lines, robotic welding systems, and precision-fitted mechanical structures., particularly for laser-cut sheet metal parts that require precise finishing for improved safety, assembly efficiency, and coating performance. However, the DM1600 2C EVO is the ideal solution for customers requiring double-sided edge rounding, offering top and bottom processing for increased productivity and uniformity.

If you want to know more about this test, visit our contact page on the website https://nsmaquinas.com/contacts/ or send us an email directly to marketing@nsmaquinas.pt.