Ewag’s new Laser Line Ultra — available from Walter Ewag UK Ltd (www.walter-machines.com), part of the United Grinding Group — uses short-pulse 50W laser technology to efficiently and effectively produce the complex contours and chip-breaker designs, as well as 3-D cavities, being increasingly demanded by users of CVD diamond tooling. The tools are used for the machining of carbon fibre and special aluminium alloys.

With three laser-beam guidance axes (U, V and W) complementing a five-axis (X, Y, Z, B and C) kinematic machine concept, the Laser Line Ultra can process tool cutting edges as well as chip-breakers in a single set-up.

Furthermore, an integrated 3-D measuring probe is used to precisely calibrate the brazed diamond plates. The laser directly vaporises tooling materials without significant heat input (cold ablation) and, unlike tool grinding and eroding, does not require coolant supply.

The laser-beam path is fully encapsulated and protected from external influences in a protected atmosphere under a slight positive pressure. The laser source and relevant optical elements are integrated into the water cooling circuit (the machine has water-cooled drives) to ensure high levels of process stability.

The laser control and water heat exchanger are integrated into the machine software and structure respectively; flue gases and evaporated material are extracted very close to the process by a unit that conveys them into an extraction/filter system.

The machine has X, Y and Z axes traverses of 400, 180 and 150mm respectively. Furthermore, its tool-holding fixture (mounted to the C axis) can be equipped with a mechanical or vacuum clamping system for ‘plate-shaped’ tools; it is also available with an automatic HSK63 interface for round tools up to 150mm in diameter.

A six-axis articulated-arm robot is used for automatic load/unload and operates in conjunction with two pallets. The entire system requires a floor space of just 5 sq m.