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

Note: Refer to your laser cutting machine manual for model-specific settings (e.g., FM series defaults).

✔ 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