Archive for the ‘Plasma Cutters’ Category

An overview of CNC plasma cutting

Thursday, February 25th, 2010

The CNC (Computer Numerical Control) plasma cutting has been prevailing since many years. But due to the high costs of machinery, it was not affordable to the small industries. Recently it has become affordable enough for all industries.

Generally, the plasma cutting process is known for its surgical precision. In the manual plasma cutters, the plasma cutting torch is being handled by humans. As a result, a kind of roughness is sometimes found in the plasma cut pieces. With the advent of CNC plasma cutting, the process has been more precise. In the CNC plasma cutting systems, the operator’s personal computer is been used to control the cutting torches and also creates the shapes to be cut. This process enables to cut intricate curves, inside cuts and sharp edges with a smooth precision that is usually possible only with hand saw. The computer is capable of controlling the movement of the plasma cutting torch as it turns it slightly before the process so that it would burn through the material first.

With the advent of technology, the CNC plasma cutting equipment has become capable of multi-axis cutting of thick material. This enables complex welding which is not possible in other plasma cutting systems. However, for cutting extremely thinner material, laser cutting with superior hole-cutting abilities has been used. The HVAC industry had also been utilizing CNC plasma cutters where the software would process information and creates patterns which have to be cut by plasma cutting torch. The technology has enhanced the HVAC industry since its introduction.

The CNC plasma cutting machines have undergone many developments in recent years. Horizontal cutting tables were used in the machines earlier but with further research and development, vertical CNC plasma cutting machines were introduced. The advantages of these machines include small foot print, flexibility, more safety, fast process, maximum utilization of energy and moreover eco friendliness.

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Things to know before buying a plasma cutter

Tuesday, February 23rd, 2010

Plasma cutters are available in different shapes and sizes and it is really confusing to select a perfect model. Before buying the plasma cutter you must have a clear idea about its usage and your needs.

Generally plasma cutters cut anything including aluminum, copper, stainless steel and other steels. For determining the thickness of the piece you are cutting, you must know the type of the metal being used. For cutting a quarter inch metal, you would need a plasma cutter that would cut cleanly, quickly and efficiently. Once you know about the type and thickness of the metal, you must decide upon the speed in which the cutting should be done. A bigger machine is required for faster cutting of metal. Here you have to consult an expert before going for a big machine since the machine would be tough to handle.

A high power plasma cutting equipment would require high voltage. So if you are buying a high power cutter, you should enquire about the voltage required and also about the availability of such high voltage in the work environment. If you are opting for a portable plasma cutter, then size and weight should be the prime concern. Plasma cutters which can be put inside a box in your truck to be carried to the work site are available in the market.

Plasma cutters are commonly operated using inert gas (often compressed air). Before buying the compressed air, you must know the Cubic foot per minute i.e. CFM of the compressor and it has to be at correct levels for the accurate operating of plasma cutters. Information on the proper gas supply could be sought by knowing the pounds per square inch (PSI) that the plasma cutter requires to run.

The most important thing before operating a cutter is that you must strictly follow the plasma cutter safety guidelines. Operating a plasma cutter is very much different than regular welding. So it would be better to take all the needed precautions.

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Overview of Plasma Torches

Saturday, January 9th, 2010

Plasma torches are producing an arc, which struck normally as a direct arc between central electrode and the welding nozzle.

Different kinds of Plasma torches are available in the markets,

Benefits of Using Plasma Torch

  • Low Power Consumption
  • Cost Effective
  • Easy to Operate
  • No electronic circuit.
  • Minimum cost of spares
  • Light Weight
  • Better Efficiency
  • Time Save
  • Spares availability
  • Higher cut quality
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How does Plasma Cutters Work?

Tuesday, December 22nd, 2009

Plasma Cutter has been around for 50 years. This course was so effective it was widely accepted by manufacturing and production companies as it considered the best way to cut metal. Fabricators realized the cutting quality and the efficiency of the cut was a great addition to the manufacturing world.

In recent years with the improvement of transformer unit and plasma cutter inverter technology, Plasma Cutter have become more affordable and obtainable to small fabrication shops, auto body shops, manufacturing plants, welding professionals, welding hobbyists, and garage shop owners. Longevity has been a principal manufacturer of affordable Plasma Cutting and welding equipment allowing even more individuals the opportunity to use, feel, and own a plasma cutter due to the low cost pricing.

Working Process of Plasma Cutter

The Plasma Cutter process works when gas (mainly compressed air) blowing all the way at high rates combined with electrical energy forming an arc that is extremely hot causing metal to melt away while blowing off the slag.

Plasma Cutter Applications

Plasma cutting is an excellent alternative for most cutting applications, as it cuts both ferrous and nonferrous materials, but it is predominantly well-suited for those in which speed and cut quality are important.
Plasma cuts with stumpy or no heat-affected zone, especially on thin metals. However, plasma cutting has its own limitations. It ruins cost-effective to cut thicker ferrous materials with oxyfuel.

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Operating Procedures of Plasma Arc Cutter

Wednesday, December 16th, 2009
  1. To start the plasma arc cutter make sure the air pressure is an adequately around 70 p.s.i. for most plasma arc cutter units and the ground clamp is attached
    to the work piece.
  2. Turn the plasma arc cutter on and regulate the amperage the manufacturers specifications for the thickness of metal to be cut.
  3. Position the defensive cup over the metal, press the igniter button and permit the arc to become established. Next, move the arc over the cut line and create the cut.
  4. The thicker the metal the slower the travel speed must be to get a good cut and vice versa. The quality of the cut generally decreases as the metal thickness increases and the travel speed decreases.
  5. A guide bar may be used to help to get good straight cuts.
  6. The shielding cup and contracting nozzle should be held approximately 1/8″ to 1/4″ above the metal being cut. The operator should avoid dragging the contracting nozzle and shielding cup on the metal when making the cut except they are specifically designed to touch the base metal while cutting.
  7. Always make cuts on the waste side of the cut line.
  8. Avoid cutting with the plasma arc cutter in damp or wet locations. The hazards of electrical stock really increased.
  9. If plasma arc cutting over an open drum with a grate be aware that the fume plume will be directed back toward the operator. Avoid this condition if at all possible, otherwise limit the exposure to fumes to short duration’s.
  10. Cuts with the plasma arc cutter may be made by moving forward, backward, or sideways. Establish which direction is easiest for you and use that process as often as possible.
  11. Always shift the plasma arc cutter as fast as possible when making a cut. This increases time efficiency, improves the cut quality, and reduces the build up of dross.
  12. Compressed air used in plasma arc cutter should be dry or the cutter will not give way to a quality cut or it not cut at all. An auxiliary air filter may be place in the compressed air line to condition the air for a plasma arc cutter.
  13. Always turn the plasma arc cutter off before resting the torch down and leaving the work area.
  14. If the quality of the cut deteriorates to an intolerable level either the constricting nozzle, the electrode, or both may need to be changed. The electrode on most plasma arc cutter will have a life of about twice the life of the constraint nozzle. Keep a supply of constricting nozzles and electrodes on hand as they deteriorate quickly during continuous use. Turn the plasma arc cutter off to put on replacement parts. Keep the plasma arc cutter torch leads and ground lead stored so they will not be cut or damaged when not in use.
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Things To Remember When Using Plasma Cutting Machine

Tuesday, December 15th, 2009
  • Replace all damaged parts
  • Check the electrode and cutting tip earlier to each cutting session or after extended usage
  • The electrode will probably be the first part to wear out.
  • Turning up the amps on a damaged electrode will not allow you to cut better, and you risk damaging the cutting torch.
  • If you restore and parts, make sure the gas dispenser goes back on in the proper direction.
  • Ensure cutting chart in metal shop for proper cutting speed and cutting amps.
  • Be aware of splash back towards you when making a sharp cut. Drill a hole first if you need.
  • Excess dross, which should be least if cutting speed and amps are right, can be knocked off simply right after cutting is done.
  • If water comes out of the cutting tip, STOP IMMEDIATELY. This means the air filter needs to be changed.
  • Do not drop sharp objects onto any of the plasma cutting wires.
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Security while using a plasma cutting machine

Thursday, December 10th, 2009

Welding is well known to be a job of dangerous nature. A simple mistake would cost you as dear as your life as well. But proper arrangements and safety measures put together with utmost presence of mind of the welder will result in harmless welding.

- Ensure that you follow the manufacturer’s instruction manual rigorously. These manuals come along with the plasma cutting machine that you buy. Proper welding helmet, clothing, gloves etc should be worn throughout the welding process.
- The manual also holds information regarding the maintenance procedure that will keep the plasma cutting machine working well long after the warranty period has elapsed. Follow the methods that are specified to achieve the same.
- Also take care that you know the dos and don’ts of handling and applying the machine to welding processes.
- Before starting to weld check if the machine is in proper condition. Do not hit the torch on surfaces that are hard.

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Plasma Cutters Are Worth A Purchase

Tuesday, December 1st, 2009

One of the most dangerous and taxing job that requires both mental and physical fitness of a person is welding. It is a risky affair to weld. If you are a professional welder you should follow the safety procedures to safeguard you and your environment. For this strictly follow the procedures enlisted in the manufacturer’s manual. Buy the necessary equipment and work at ease with presence of mind.

Apart from this you will be expected to give clean welds at you job too. For this you can rely upon a plasma cutter. This is a machine which can definitely be called as the magic wand of any welder. A plasma cutter provides great quality cuts on any metals. This is the uniqueness of the machine and sure it is a best buy for any welder. Highly charged plasma is responsible melt the required metal at the specific point that is required. Thereby it affects not the surrounding material.

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When To Use A Plasma Cutting Machine

Wednesday, November 18th, 2009

A plasma cutting machine is a wonderful tool that produces great welds at wonderful speed. While you determine if your task needs the help of a plasma cutter ask yourself the below listed questions;

  • What cover the maximum expenditure in your repair or manufacturing process?
  • What are the significant issues related to quality?
  • What does the cutter offer as a topping to your task?
  • What is your ability to weld and maintain them?

You can go ahead;

  • If the major cost is related to finishing or cutting then plasma cutter is a huge cost saver.
  • If your issues are huge on strict quality then the cutter is a magic wand in your hand. It can keep warping to a bare minimum and provide full control of the arc.
  • The cutter is a great tool to offer fine welds on thin materials with less warping in the process.
  • A moderate to expert ability level is required to get the most out of the cutter.
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Applications of a Plasma Cutter

Tuesday, November 17th, 2009

There are a variety of applications of a plasma cutter. Few of the lesser known areas where the plasma cutter shines bright are listed below with a brief explanation;

Metal Artwork:
They myth that said that a plasma cutter is incapable of providing precision cutting is busted with this application that a plasma cutter effortlessly provides. Intricate work of art can be achieved with the help of the cutter.

Roofing and Siding:
Thin steel is used to do roofing and siding, to mend it a controlled arc is necessary. Solution is the plasma cutter. The cutter produces minimum or no warping as its arc is at control with high speed travel. It is easy to trace templates, create holes for air conditioners etc.

Solid Waste Removal:
To get rid of existing welds the cutter is used as a efficient tool. Repair works are done within a minimum stipulated time.

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