Patent Publication Number: US-2021162534-A1

Title: Laser assisted machining of sheet material

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/657,242, filed Apr. 13, 2018, the disclosure of which is incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     This application is directed generally to methods and systems for fabricating components from sheet stock, and more specifically laser machining of sheet stock in tool and die fabrication processes and systems. 
     BACKGROUND OF THE DISCLOSURE 
     A wide range of sheet metal parts are manufactured by stamping and punching from sheet stock. Conventionally, the gap between the die and punch requires tight clearances, typically 5% to 15% of material thickness. For thin sheet stock, the die and the punch must be machined within tolerances to provide the required fit. 
     Furthermore, certain materials are not conducive to stamping or punching. An example of difficult materials to stamp or punch is electrical steels, which, due to normal wear and tear of the stamps and dies, will eventually produce the parts with unsatisfactory edge quality or damage to (cracking of) the sheet itself. Because of the high forces that repeatedly act on the tools, the rate of wear on the tools can be quite high, thus requiring frequent refurbishment or replacement. 
     The tight tolerances required for stamping of thin sheets, in addition to the need to frequently refurbish or replace, makes stamping of certain materials untenable. A system and method that addresses these issues would be welcomed. 
     SUMMARY OF THE DISCLOSURE 
     Various embodiments of the disclosure describe the process of making components or parts from sheet or coil material by combining cutting, scoring and separation processes with the a flattening process. The cutting process includes cutting a partial outline of the perimeter of the component using high power energy source, such as a laser beam. The cutting process may include cutting of between 20% to 97% of the perimeter of the component. The scoring process includes scoring at least a partial outline of the component perimeter. The component perimeter is scored using high power energy source, such as a laser beam. The scoring process may include scoring of 20% to 100% of the perimeter of the component. The process of separation includes separating the component from sheet or coil, such as by a punching operation, and removing the component with compressed air or with an electromagnetic pulse. 
     In addition, a system and process where the scored portion of the sheet material that includes the scored lines is subjected to a flattening process prior to the punching operation is disclosed. Performing the flattening operation prior to the punching operation has the effect of streamlining the process. That is, the sheet material can be easily handled and conveyed from the scoring process and any cutting process, through the flattening process, and to the separation process without need for separate handling of the component. Such streamlining is of particular value when handling thin sheets that, in some cases, resemble foil material. Herein, “sheet material” is construed broadly to include conventional sheets, ribbons, thin plates, reels, coils and other such forms that may be processed in a stamping or through-punch operation. 
     The flattening process acts to return the cut and/or scored portion of the sheet material to substantially the original thickness by flattening proud features that may arise in the cutting or scoring processes, such as dross or beads of molten materials which may form at the corners of the scored grooves. The cut and/or scored portion of the sheet may undergo some degree of bowing or warping due to the temperature gradients that are incurred during the cutting and scoring processes. The flattening process may remove or diminish such bowing or warping and restore the scored portion of the sheet material to a planar state. 
     Another aspect of the disclosed systems and processes are that the score line establishes the location of a line of separation between the component and the sheet material during the separation process. If the separation process is conducted with rigid punch and die, tight tolerances between the punch and the die are not required to effect the desired shape of the component. This relaxes the tolerance requirements of the tooling, so that instead of 5% to 15% of the sheet material thickness, the die gaps may be one or two times the thickness of the sheet material or greater. Accordingly, the cost of tooling is reduced, and the tooling can experience greater levels of wear before requiring replacement or refurbishment. Furthermore, the rate of tool wear may be greatly reduced, as the forces required to shear the component at the score line is reduced relative to shearing the full thickness of the sheet material. 
     Surprisingly, we have found that, for many applications, the sequence of compressively flattening the cut and or scored portion of the sheet material before the separation process produces a finished or nearly finished component. The roughness of the edges is, for some applications, within a finished specification. Often, the dross or reformed molten material that was turned down at the corners of the cut and or scored grooves during the flattening process is pre-stressed and fatigued, and is easily removed by light finishing techniques. The components, even though produced with more generous punch and die clearances, may also retain a satisfactory planarity through the punching process. 
     Structurally, various embodiments of the disclosure include a scoring-assisted method for punching components from a sheet material, comprising scoring an outer score line on a sheet material with a high energy radiation source, the outer score line defining a shape of an outer perimeter of a component; after the step of scoring, flattening a scored portion of the sheet material with a flattening device, the scored portion of the sheet material including the outer score line; and after the step of flattening, driving a component punch through the sheet material to separate the component from the sheet material, the component punch contacting the sheet material within the outer score line. In some embodiments, the high energy radiation source in the step of scoring an outer score line on the sheet material is a laser. 
     The method may include, before the step of flattening, cutting a discard out of the sheet material with the high energy radiation source to separate the discard from the sheet material. Alternatively, in some embodiments, before the step of flattening, the method includes scoring a discard score line on the sheet material with the high energy radiation source, the discard score line defining a shape of an outer perimeter of a discard, the discard score line being surrounded by the outer score line. Before the step of driving the component punch, the method may include driving a discard punch through the sheet material to separate the discard from the sheet material, the discard punch contacting the sheet material within the discard score line. Before the step of driving the discard punch, the method may include aligning the outline with a discard die, the discard die being positioned and configured to receive the discard punch. In some embodiments, the method includes configuring the discard punch to be inserted within the discard die to define a minimum die clearance gap that is at least one and not more than three times a thickness of the sheet material. 
     In various embodiments, before the step of driving the component punch, the method includes aligning the outer score line with a component die, the component die being positioned and configured to receive the component punch. The method may also include configuring the component punch to be inserted within the component die to define a minimum die gap clearance that is at least one and not more than three times a thickness of the sheet material. In some embodiments, the flattening device in the step of flattening is a compressive roller. A roller pressure may be applied by the compressive roller during the step of flattening that is less than a yield strength of said sheet material. 
     In some embodiments, the method includes providing the sheet material having a thickness in a range of 20 micrometers to 400 micrometers inclusive. The sheet material may be of a metallic material, and may also be of an amorphous metal, and furthermore of silicone steel. In some embodiments, the step of scoring defines a groove depth that is in a range of not less than 20% and not more than 80% of a thickness of the sheet material. In some embodiments, after the step of scoring and before the step of driving, the method includes removing surface debris from the portion of the sheet material. The step of removing loose material may be performed with compressed air. 
     In various embodiments of the disclosure, a scoring-assisted system for manufacturing components from a sheet material is disclosed, comprising a conveyor for conveying a sheet material along a conveyance path, a high energy radiation source for forming an outer score line on the sheet material that defines a shape of an outer perimeter of a component, a flattening device for flattening the sheet material, a component punch for separating a component from the sheet material at the outer score line, and a component die configured to receive the component punch. In some embodiments, the flattening device is disposed between the high energy radiation source and the component punch along the conveyance path. The high energy radiation source may be configured for cutting a discard from within the outer score line to separate the discard from the sheet material. 
     Alternatively, the high energy radiation source may be configured for forming a discard score line that is surrounded by the outer score line, the discard score line defining a shape of an outer perimeter of a discard. In such embodiments, the system may include a discard punch for separating the discard from the sheet material at the discard score line, and a discard die configured to receive the discard punch, wherein the discard punch is disposed between the flattening device and the component punch along the conveyance path. 
     The scoring-assisted system may be configured to handle a sheet material having a thickness in a range of 20 micrometers to 400 micrometers inclusive. In some embodiments, the high energy radiation source is a laser. In some embodiments, the flattening device is a compressive roller. The compressive roller may be configured to apply a roller pressure on the sheet material that is less than a yield strength of the sheet material. The high energy radiation source may be configured to form a groove depth that is in a range of not less than 20% and not more than 80% of a thickness of the sheet material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial perspective view of a scoring-assisted system according to an embodiment of the disclosure; 
         FIG. 2  is a partial perspective view of a scoring-assisted system including a discard punch and die, according to an embodiment of the disclosure; 
         FIG. 3  is an end sectional view of score line grooves before and after flattening, according to an embodiment of the disclosure; 
         FIG. 4  is a cutaway view of a scored tab bridging a through-cut according to an embodiment of the disclosure; 
         FIG. 5  is a plan view of a perforated score line according to an embodiment of the disclosure; 
         FIG. 6  is a side sectional view of the perforated score line of  FIG. 5  according to an embodiment of the disclosure; 
         FIG. 7  is a side sectional view of an alternative perforated score line according to an embodiment of the disclosure; 
         FIG. 8  is a side sectional view of another alternative perforated score line according to an embodiment of the disclosure; 
         FIG. 9  is a perspective view of a discard punch and a discard die in alignment with a scored section of a sheet material, according to an embodiment of the disclosure; 
         FIG. 10  is a perspective view of a component punch and a component die in alignment with a scored section of a sheet material with a discard removed, according to an embodiment of the disclosure; 
         FIG. 11  is an elevational, partial cutaway view of a punch centered over a sheet material and a die, according to an embodiment of the disclosure; 
         FIG. 12  is an enlarged, partial view of the cutaway of  FIG. 11  depicting a die clearance gap, according to an embodiment of the disclosure; 
         FIG. 13  is an elevational view of a punch inserted through the sheet material and into the die of  FIG. 11 , according to an embodiment of the disclosure; 
         FIG. 14  is a sectional view at plane A-A of  FIG. 13  for a discard punch inserted in a discard die according to an embodiment of the disclosure; 
         FIG. 15  is a sectional view at plane A-A of  FIG. 13  for a component punch inserted in a component die according to an embodiment of the disclosure; 
         FIG. 16  is a graph of a cutting depth of a groove versus a scanning rate for a single pass of a 1 kilowatt Ytterbium single-mode continuous wave cutting laser according to an embodiment of the disclosure; and 
         FIG. 17  is a graph of a cutting depth of a groove versus a number of passes for a 1 kilowatt Ytterbium single-mode continuous wave cutting laser at a scanning rate of 20 meters per second according to an embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE FIGURES 
     Referring to  FIG. 1 , a scoring-assisted system  30   a  for fabricating components  32  from a sheet material  34  is depicted according to an embodiment of the disclosure. In the depicted embodiment, the scoring-assisted system  30   a  includes a scanning radiation source  42 , a sheet flattening device  44 , a component punch  48 , and a component die  54 . Also in the depicted embodiment is an air nozzle  56  directed at the sheet material  34 . A discard bin  72  may be configured to receive discards  74  that are removed from the sheet material  34  by scanning radiation source  42 . The discards  74  may be a single continuous piece (depicted) or may be a plurality of pieces (e.g., a plurality of isolated apertures). Likewise, a component bin  75  may be configured to receive components  32  that are removed from the sheet material  34  by the component punch  48 . 
     Referring to  FIG. 2 , a scoring-assisted system  30   b  for fabricating the components  32  from the sheet material  34  is depicted according to an embodiment of the disclosure. The scoring-assisted system  30   b  includes many of the same components and attributes as the scoring-assisted system  30   a , which are indicated with same-numbered reference characters. In addition, the scoring assisted system  30   b  includes a discard punch  46  and a discard die  52 . The air nozzle  56  is not depicted in  FIG. 2 , but it is contemplated that the air nozzle  56  may be utilized in the scoring-assisted system  30   b  as well. For the scoring-assisted system  30   b , the discards  74  are generated by actuation of the discard punch  46 , so the discard bin  72  is positioned and configured to receive the discards  74  from the discard die  52 . 
     The scoring-assisted systems  30   a  and  30   b  are herein referred to generically or collectively as scoring-assisted system(s)  30 . The scoring-assisted systems  30  are configured to convey the sheet material  34  in a direction  62  along a conveyance path  64  so that a given portion of the sheet material  34  is conveyed under the scanning radiation source  42 , through the sheet flattening device  44 , and between the component punch  48  and component die  54  in sequence. 
     The scanning radiation source  42  delivers a concentrated beam of radiation  80  and may be configured to rapidly trace an outline  82  of the component  32  on the sheet material  34 . Examples of rapid moving radiation sources are found, for example, at U.S. Pat. No. 9,649,727 to Kancharla and owned by the owner of the present application, the disclosure of which is hereby incorporated by reference herein in its entirety except for express definitions and patent claims contained therein. The scanning radiation source  42  may be a laser  88 . The laser  88  may be either continuous wave (CW) or pulsed. A non-limiting example of a suitable laser includes a Ytterbium single-mode CW laser, such as the YLR-1000-WC-Y14 manufactured by IPG Photonics. Other single mode lasers of sufficient power, pulses or continuous wave, may be utilized. A beta radiation source (i.e., electron beam) is also contemplated for use as the scanning radiation source  42 . In some embodiments, the radiation source  42  is configured to deliver power within a range of 0.5 kW (kilowatts) to 2 kW inclusive. Herein, a range that is said to be “inclusive” includes the end point values of the range as well as all intermediate values within the range. 
     The portion of the sheet material  34  on which the outline  82  is scored is referred to herein as the scored portion  83  of the sheet material  34 . In the depicted embodiment, the outline  82  includes an inner or discard score line  84  and an outer score line  86 . The inner score line  84  traces an outer perimeter  85  of the discard  74 . The outer score line  86  traces an outer perimeter  87  of the component  32 . The inner and outer score lines  84  and  86  combine to define the boundaries of the component  32 . The scanning radiation source  42  may be configured to score the outline  82  to a desired depth within a thickness t of the sheet material  34  (e.g.,  FIG. 12 ) over multiple passes. Non-limiting examples of the desired depth of the score lines  84  and  86  is in a range of 20% to 80% inclusive of the thickness t of the sheet material  34 . In some embodiments, the thickness t is in a range of 20 μm (micrometers) to 400 μm inclusive. 
     The air nozzle  56  may be stationed to between the sheet flattening device  44  and the component punch  48  (depicted). Alternatively, the air nozzle  56  may be stationed between the scanning radiation source  42  and the sheet flattening device  44 . In some embodiments, an additional air nozzle is incorporated so that an air nozzle is stationed on both sides of the sheet flattening device  44 . The air nozzle  56  may be configured to deliver an air jet in a manner that sweeps laterally across the sheet material  34  (depicted). In some embodiments, the air nozzle  56  is configured to trace over the outline  82  at close proximity to the sheet material  34 . In some embodiments, the score lines  84 ,  86  may be cleaned of surface debris by devices and techniques other than air nozzles  56 , such as brushes, air knife, or water rinse. The cleaning of surface debris may occur before the flattening process, after the flattening process, or both. 
     Referring to  FIG. 3 , the effect performing multiple passes with the scanning radiation source  42  to form the score lines  84  and  86  is depicted according to an embodiment of the disclosure. The score lines  84  and  86  define a groove  96  having a depth d within the thickness t of the sheet material  34 , with a web portion  98  that bridges the sides of the groove  96 . The scoring of the sheet material  34  with the concentrated beam of radiation  80  causes some reformed molten and dross material  102  to collect at corners  104  of the groove  96  and to extend proud of a surface  106  of the sheet material  34 . In the depicted embodiment, some of the sheet material  34  is removed from the groove  96  by vaporization, so that the volume and mass of the reformed material  102  is only a fraction of the total of the sheet material  34  that is removed from the groove  96 . 
     In some embodiments, the scanning radiation source  42  is configured to scan the outline  82  at a rate that is in a range from 5 ms (meters per second) to 30 ms inclusive. In some embodiments, the scanning radiation source  42  delivers radiation in a range of 0.1 kW to 2 kW inclusive. The depicted cross section of the groove  96  of  FIG. 2  is a non-limiting rendering of a photograph taken of a cross-section of a sheet material  34  of mild steel of 97 μm nominal thickness that was scanned with a 1 kW laser a total of four times at a scanning rate or 20 ms. Results for the same scoring parameters on a sheet of silicon steel were similar. For both mild steel and silicon steel, under the stated scoring conditions, the thickness of material removed from the groove  96  for each pass of the scanning radiation source  42  has been observed to be in the range of 15 μm to 35 μm inclusive, with a nominal thickness of removed material to be 16 μm to 20 μm inclusive. Data for a cutting depth of mild steel and silicone steel at varying scan rates and numbers of passes are presented below at  FIGS. 16 and 17 . 
     Functionally, by forming the score lines  84  and  86  over multiple passes, the heat affected zone of the sheet material  34  is reduced relative to that of a single pass that dwells long enough to form the groove  96 . Also, because less of the energy delivered by the concentrated radiation beam  80  is absorbed by the sheet material  34 , the amount of material vaporized during the successive passes may be increased relative to a single pass formation or a groove of similar depth. Also, irregularities that may be formed on the sides of the groove  96  (e.g., by reformation of dross) during initial passes may tend to be ablated away in successive passes to form a cleaner, better defined groove  96 . 
     In some embodiments, one contour line may be completely through-cut while another contour line may be scored. Such an arrangement is depicted in scoring-assisted system  30   a , where the discard  74  is completely through-cut by the scanning radiation source  42 , while the outer score line  86  remains. This arrangement negates the need for the discard punch process, while leaving the component  32  attached to the sheet material  34  for conveyance along the conveyance path  62  through the sheet flattening device  44  and onto the component die  54 . 
     Referring to  FIG. 4 , a scored tab configuration  100  is depicted according to an embodiment of the disclosure. In this embodiment, scoring is combined with through-cutting so that a portion or the contour line of the component  32  is cut through the thickness t of the sheet material  34  while material remains along another portion of the contour line. For example, one or both of the perimeters  85 ,  87  may include a through-cut portion  91  and a tab portion  93 , the tab portion  93  bridging the through-cut portion  91 . In some embodiments, the tab portion  93  is scored with the groove  96  in the manner depicted in  FIG. 3 . In some embodiments, a plurality of such tab portions  93  are formed along the perimeter(s)  85 ,  87 . In some embodiments, a ratio of a sum of the tangential lengths  95  of the tabs  93  to a total length of the corresponding perimeter  85 ,  87  is in a range of 50% to 97% inclusive; in some embodiments, the ratio is in a range of 75% to 95%; in some embodiments, the ratio is in a range of 85% to 95%. 
     Functionally, the tabs  93  maintain coupling between the component  32  and the sheet material  34  or between the coupling  32  and discard  74  and the sheet material  34 , enabling the component  32  or the combined component  32  and discard  74  to be stably conveyed along the conveyance path  64  with the sheet material  34 , for positioning over the component die  54  or both the discard die  52  and the component die  54  in sequence. The reduced bridging between the discard  74  and component  32  and between the component  32  and sheet material  34  relative to a conventional stamping process reduces the required separation forces. In embodiments where the tab portions  93  are scored, the forces are further reduced and the line of separation may be predictable within a tighter tolerance than with tab portions  93  that are not scored. 
     In the depicted embodiment, the sheet flattening device  14  is a roller assembly  90  that includes opposed rollers  92 ,  94  on opposing sides of the sheet material  34 . The opposed rollers  92 ,  94  may be coupled to roller mounts  89  that are configured to limit separation of the rollers  92 ,  94  at a maximum predetermined distance. In some embodiments, the maximum separation of the rollers  92 ,  94  is set to be at least the nominal thickness t of the sheet material and no greater than 1 μm more than the nominal thickness t. In some embodiments, the roller mounts  89  are configured to provide rigid separation of the rollers  92 ,  94 . Contact of each roller  92 ,  94  with the sheet material  34  may be established by an electrical contact measurement. In some embodiments, the rollers  92 ,  94  are of a hard metallic material. In some embodiments, the rollers  92  and  94  operate at different electrical potentials, thereby causing a current to flow through the sheet material  34  during conveyance through the roller assembly  90 . 
     Functionally, limiting the separation between the rollers  92 ,  94  to a maximum dimension at the nominal thickness t or rigidly maintaining the separation at the nominal thickness t of the sheet material  34  enables the roller assembly  90  to perform the flattening function without exerting substantial stresses on the core of the sheet material. As the scored portion  83  of the sheet material passes through the roller assembly  90 , only the proud features relative to the surface  106 , such as the reformed molten and dross material  102  at the corners  104  ( FIG. 3 ), exceed the nominal thickness t of the sheet material  34  and come into compressive contact with the rollers  92 ,  94 . Because the separation between the rollers  92 ,  94  do not exceed or are held constantly at the nominal thickness t, the reformed molten and dross material  102  will yield locally to the rollers  92 ,  94 , resulting in plastic deformation that turns these features down. 
     Accordingly, the scored portions  83  of the sheet material are flattened without generating substantial Hertzian contact stresses. Hertzian contact theory characterizes the stresses generated by the contact of curved stresses, and is described, for example, at Xiaoyin Zhu, “Tutorial on Hertz Contact Stress”, available at https: wp.optics.arizona.edu.optomech.wp-content/uploads.sites.53 2016 10.OPTI-521-Tutorial-on-Hertz-contact-stress-Xiaoyin-Zhu.pdf, last visited on Mar. 27, 2018, the disclosure of which is incorporated by reference herein in its entirety except for express definitions contained therein. Excessive Hertzian contact stresses are known, for example, to adversely affect the magnetic properties of materials. 
     Alternatively, the roller assembly  90  may be a compressive roller configured to compress the sheet material  34  therebetween using a predetermined force as the sheet material  34  is conveyed through the roller assembly  90 . Compression between the rollers  92 ,  94  may be accomplished, for example, with hydraulic actuators (not depicted). The predetermined force generated by the roller assembly  90  may be tailored to deliver stresses on the sheet material  34  that do not exceed the yield strength of the material. Because the reformed molten and dross material  102  stands proud relative to the surface  106  of the sheet material  34  and constitutes a small fraction of the total line contact of the roller assembly  90 , the local stresses on the reformed molten and dross material  102  will far exceed the average stress on the sheet material  34 , thereby preventing deformation of the core of the sheet material  34  while still providing flattening (plastic deformation) of the reformed molten and dross material  102 . In some embodiments, the roller assembly  90  is configured to apply a compressive force on the sheet material  34  only when the sheet material  34  is moving through the roller assembly  90 . Alternatively, the flattening device  44  may include a flat stamping plate (not depicted), a rocking press (not depicted), or other devices and techniques for flattening sheet material available to the artisan. 
     The effect of flattening the sheet material  34  after scoring but prior to punching is also depicted in  FIG. 3  according to an embodiment of the disclosure. The sheet material  34  is advanced through the roller assembly  90  so that the reformed material  102  is flattened (i.e., made substantially planar with the surface  106 ). For some materials, such as mild steel and amorphous silicon steel, the reformed material  102  is relatively ductile, so that the reformed material is turned down at the corners  104 . Also, some reformed material that is tenuously attached to the corners  104  may be pre-stressed and fatigued or fractured and detached during the flattening process. Operating the rollers  92 ,  94  at different potentials may provide local heating of the sheet material  34  to augment the flattening process. The electrical current also interacts with the core of the component  32  to augment plastic deformation desirable in the flattening process. 
     Accordingly, to “flatten” the sheet material  34  is to compress or return the reformed molten and dross material  102  to be substantially at or within the original thickness t of the sheet material  34 , and to mitigate bowing and warping of the sheet material. That is, the sheet material  34  will still define the outline  82  after the flattening process. The flattening process does not compress the sheet material  34  to the point of eliminating the score lines  82  and  84 . 
     In some embodiments, the compressive force is applied by the roller  90  only when the sheet material  34  is advanced therethrough. By applying the compressive force with the roller assembly  90  only when the sheet material  34  is passing through the roller assembly  90 , the system avoids dimpling of the sheet material  34  that may otherwise occur as the material dwells momentarily within the rollers  92 ,  94 . 
     Referring to  FIGS. 5 through 8 , a perforated score line  108  is depicted in an embodiment of the disclosure. The perforated score line  108  is characterized as having perforations  110  formed along the length of the web portion  98  within the groove  96 . In some embodiments, at least a portion of one or both of the discard score line  84  and the outer score line  86  of the score outline  82  is formed with such perforated score lines  108 . The perforated score line  108  may be formed over multiple passes as discussed above. In  FIGS. 5 and 6 , the score outline  82  is initially formed as being continuous and of substantially uniform depth, followed by bursts of radiation energy at discrete points along the length of the groove  96  to form the perforations  110 . In some embodiments, only the perforations are formed by the scanning radiation source  42  ( FIG. 7 ). That is, the scoring-assisted systems  30  are configured so that the scanning radiation source  42  delivers bursts of radiation only at the desired locations of the perforations  110  to form a discontinuous scoring outline  82 . In some embodiments, the scan rate is undulated so that the concentrated radiation beam  80  dwells or passes more slowly over the regions where the perforations  110  are to be formed ( FIG. 8 ). After formation of the perforated score line  108 , the sheet material  34  with score lines  82  and  84  thus formed may be compressively flattened as described above. 
     Functionally, the perforations  110  serve to reduce the forces required to separate the components  32  or the discards  74  or both from the sheet material  34 . Any dross material that may be formed along the boundaries of the perforations  110  may be flattened or removed by the flattening device  44  in the same manner as the corners  104  described above. The perforations  110  may also serve to limit the effect of tearing or ripping along the lines of separation and to keep the lines of separation centered along the web portion  98 , so that the nominal peripheries of the components  32  are substantially uniform. 
     Referring to  FIG. 9 , the discard punch  46  and discard die  52  are depicted according to an embodiment of the disclosure. The discard punch  46  and discard die  52  are so-named because they function to remove the discards  74  from the sheet material  34  that is not part of the finished component  32 . The discard punch  46  may define a footprint  112  that approximates but is within the inner or discard score line  84  of the discards  74 . The discard die  52 , when utilized, is configured to receive the discard punch  46  and may define a footprint  114  that approximates but is within the discard score line  84  of the outline  82 . 
     Referring to  FIG. 10 , the component punch  48  and component die  54  are depicted according to an embodiment of the disclosure. The component punch  48  and component die  54  are so-named because they function to remove the components  32  from the sheet material  34 . The component punch  48  may define a footprint  142  that approximates but is within the outer score line  86  of the components  32 . The component die  54 , when utilized, is configured to receive the component punch  48  and may define a footprint  144  that approximates but is outside the outer score line  86  of the outline  82 . In the depicted embodiment, the outer score line  86 , and therefore a receptacle  146  of the component die  54 , are circular. 
     In some embodiments, the punches  46  and  48  and the dies  52  and  54  are made of a rigid material (e.g., tooling steel) that contacts the sheet material  34 . In some embodiments, some or all of the punches  46  and  48  and the dies  52  and  54  include a semi-rigid or a flexible material that contacts the sheet material  34 , such as polyurethane or rubber-like materials. The semi-rigid or flexible material may be disposed on or integrated with the discard punch  46  or discard die  52 , for example, in an overmolding process. 
     Referring to  FIGS. 11 through 15 , operation of the discard punch  46  and discard die  52  and of the component punch  48  and component die  54  are depicted according to an embodiment of the disclosure. As operation of the discard punch  46  and discard die  52  is similar to the operation of the component punch  48  and component die  54 ,  FIGS. 11 through 13  are annotated to depict the operation of both of these punch and die combinations. After the component  32  has been scored with the scanning radiation source  42 , the inner or discard score line  84  of the outline  82  of the component  32  is aligned over the discard die  52  to define a die clearance gap  122  between the discard punch  46  and the discard die  52  ( FIGS. 11 and 12 ). The scoring-assisted systems  30  may be configured so that the score lines  82  and  84  are in the same rotational orientation as the discard punch  46  and discard die  52 , such that the discard score line  84  is positioned over the die clearance gap  122  by translating the outline  82  over the discard die  52 . When the component outline  82  is aligned with the discard die  52 , the discard score line  84  traces over the die clearance gap  122 . 
     The discard punch  46 , which aligns within the discard score line  84 , is then thrust through the sheet material  34  to separate the discard  74  from the sheet material  34  ( FIG. 13 ) at the discard score line  84 . During the separation of the discard  74 , the discard punch  46  is inserted at least partially into the discard die  52 . A cross-sectional view of the discard punch  46  within the discard die  52  is presented at  FIG. 14 , depicting a discard punch cross-section  124  and a discard die cross section  126 . In some embodiments, the die clearance gap  122  is defined laterally between the discard punch  46  and the discard die  52  when the discard punch  46  is inserted into the discard die  52 . In some embodiments, a minimum dimension  128  for the die clearance gap  122  is at least one and not more than three times the thickness t of said sheet material  34 . 
     After the discard  74  has been removed from the sheet material  34 , the outer score line  86  of the outline  82  is aligned over the component die  54 , the component  32  being radially suspended at the outer score line  86 . When in alignment, the component punch  48  and the component die  54  define a die clearance gap  162 , over which the outer score line  86  is positioned ( FIGS. 11 and 12 ). The component punch  48  is then thrust through the sheet material  34  to separate the component  32  from the sheet material  34  ( FIG. 13 ) at the outer score line  86 , so that the component  32  drops into the component bin  75 . During the separation of the component  32 , the component punch  48  is inserted at least partially into the component die  54 . A cross-sectional view of the component punch  48  within the component die  54  is presented at  FIG. 15 , depicting a component punch cross-section  162  and a component die cross section  164 . A continuous, die clearance gap  166  is defined between the component punch  48  and the component die  54 . In some embodiments, a minimum dimension  168  for the die clearance gap  16  is at least one and not more than three times a thickness t of the sheet material  34 . 
     Functionally, the score outline  82  controls the line of separation in both the discard  74  and component  32  punching processes in the scoring-assisted system  30   b . and controls the line of separation of the component  32  in the scoring-assisted system  30   a . This is in contrast to a conventional stamping process, where the line of separation is controlled by tight tolerances between tool and die. Accordingly, the tolerances between the component punch  48  and the component die  54  and, when utilized, between the discard punch  46  and the discard die  52  may be more generous. Because of the compressive rolling process that occurs after scoring and any cutting process but before the punching operation(s), at least the flatness of the component  32  is in a finished state upon separation from the sheet material  34 . The edges of the components  32  may then be finished to final specifications, for example by sand blasting, turning, milling, grinding, honing, electrical erosion, or other finishing processes available to the artisan. 
     Referring to  FIG. 16 , a graph  170  of data characterizing a cutting depth parameter  172  of a groove versus scanning rate (cutting speed)  174  of a laser is presented according to an embodiment of the disclosure. The data were obtained in an experimental setup using an IPG Photonics YLR-1000-WC-Y14 Ytterbium single-mode CW laser at a power level 1000 Watts utilizing a fiber diameter of 14 μm. The laser was scanned with an IPG 2D High Power Scanner with a 200 mm collimator and a 254 mm focus lens. The focus spot diameter was calculated at 18 μm. The tests were performed at an ABB IRB2400 robot work station in a stationary scanner set up. The tests were performed on a vacuum honeycomb cutting table with an air knife purge directed on the process area. The tests were performed on mild steel sheet stock and silicon steel sheet stock of 100 μm nominal thickness. Mild steel data  176  and silicon steel data  178  are presented in the graph  170 . 
     Data were taken for a single pass of the cutting laser at scanning rates of 7.0, 8.0, 10.0, 15.0, and 20.0 ms. The graph  170  demonstrates that cutting depth is reduced as the scanning rate is increased, and that results were substantially similar for mild steel and silicon steel. It was also observed that less dross material was formed along the boundaries at higher scanning rates. 
     Referring to  FIG. 17 , a graph  180  of data characterizing a cutting depth parameter  182  of a groove versus the number of passes  184  of a laser is presented according to an embodiment of the disclosure. The data were obtained in an experimental setup using an IPO Photonics YLR-1000-WC-Y14 Ytterbium single-mode CW laser at a power level 1000 Watts utilizing a liber diameter of 14 μm. The laser was scanned with an IPG 2D High Power Scanner with a 200 mm collimator and a 254 mm focus lens. The focus spot diameter was calculated at 18 μm. The tests were performed at an ABB IRB2400 robot work station in a stationary scanner set up. The tests were performed on a vacuum honeycomb cutting table with an air knife purge directed on the process area. The tests were performed on mild steel sheet stock and silicon steel sheet stock of 100 μm nominal thickness. Mild steel data  186  and silicon steel data  188  are presented in the graph  180 . 
     Data were taken at a scanning rate of 20 ms for the cutting laser at with the number of passes ranging from 1 to 5 inclusive. The graph  180  demonstrates that increasing the number of passes also increases the cutting depth, and that results were substantially similar for mild steel and silicon steel. It was also observed that complete cut through of the stock material was achieve at 5 passes at the 20 ms scanning rate. 
     Each of the additional figures and methods disclosed herein can be used separately, or in conjunction with other features and methods, to provide improved devices and methods for making and using the same. Therefore, combinations of features and methods disclosed herein may not be necessary to practice the disclosure in its broadest sense and are instead disclosed merely to particularly describe representative and preferred embodiments. 
     Various modifications to the embodiments may be apparent to one of skill in the art upon reading this disclosure. For example, persons of ordinary skill in the relevant arts will recognize that the various features described for the different embodiments can be suitably combined, un-combined, and re-combined with other features, alone, or in different combinations. Likewise, the various features described above should all be regarded as example embodiments, rather than limitations to the scope or spirit of the disclosure. 
     Persons of ordinary skill in the relevant arts will recognize that various embodiments can comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the claims can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. 
     Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein. 
     Unless indicated otherwise, references to “embodiment(s)”, “disclosure”, “present disclosure”, “embodiment(s) of the disclosure”, “disclosed embodiment(s)”, and the like contained herein refer to the specification (text, including the claims, and figures) of this patent application that are not admitted prior art. 
     For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. 112(1) are not to be invoked unless the specific terms “means for” or “step for” are recited in the respective claim.