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Problem Description
Many users report that after prolonged use, their laser cutting machine begins producing imperfect round holes (e.g., 30mm diameter). Instead of clean circles, cuts appear oval or polygonal, significantly affecting part accuracy.
Root Causes of Non-Round Holes in Laser Cutting Machines
1. Incorrect Motion Parameters
Excessive acceleration/jerk settings cause mechanical stress on gears
High idle speed (>40mm/min) worsens wear over time
Corner smoothing (low-pass filter) set too high (>4Hz) distorts circular paths
2. Mechanical Wear in Drive Systems
Gear & rack backlash develops from prolonged use
Worn-out reducer gears lose positioning precision
Improper meshing clearance (should be 0.06mm for X/Y axes)
3. Failed Motion Components
Severely damaged reducers cannot maintain accuracy even after adjustment
Proven Solutions to Restore Round Cutting Accuracy
✔ Parameter Optimization for Laser Cutting Machines
Parameter
Recommended Value
Cutting Acceleration
≤0.4G
Idle Speed
≤40mm/min
Corner Low-Pass Filter
≤4Hz
✔ Gear/Rack Maintenance Procedure
Check backlash using 0.5mm solder wire
Adjust meshing clearance to 0.06mm (X-axis single drive) / 0.06mm x2 (Y-axis dual drive)
Re-tighten all mounts with torque wrench
✔ When to Replace Components
If holes remain distorted after:
Parameter adjustments AND
Mechanical recalibration → Replace the reducer
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