A plasma is a state of matter like a solid, liquid or gas. The xpr170 mechanized plasma cutting system delivers next generation xdefinition processes from very thin up to midrange thicknesses. Mar, 2020 plasma arc cutter equipment schematic diagram plasma arc equipment controls. Like a router, the direction of travel the plasma torch takes will affect the cut quality. Plasma arc cutting process and equipment considerations twi. Plasma arc cutting is a process in which an electronic arc ionizes a gas, creating a superheated plasma arc column used to cut ferrous and nonferrous metal alloys. Chapter 1 early plasma cutting the plasma arc cutting process saw its first commercial application in the early 1960s.
Zeny cutter machine by using inverter technical of switch power. Typical materials cut with a plasma torch include steel, stainless steel, aluminum, brass and copper, although other conductive metals may be cut as well. As i began mounting my parts, i organized my board into four sections. Create your own cutting diagrams kreg tool company. As the ionized gas plasma arc is swirled, the electrical arc will attach itself evenly to the leading. Plasma cutter not arcing proved 7 troubleshooting methods. Some tips and suggestions for best practices that will increase your efficiency and precision and prolong the life of your plasma cutter and consumables include. If you are experiencing issues starting the cutter, first check the pilot arc. A youtube viewer gave me a faulty lotos plasma cutter ltp5000d to see if i could repair the unit. Make sure that you either have a water separator on your plasma cutter or that you have a water separator in line with your air compressor before the air is delivered to your plasma cutter.
Pdf experimental investigation of the plasma arc cutting. Apr 24, 2020 the plasma arc cutting process cuts metal by melting a section of metal with a constricted arc. Zeny dc inverter plasma cutter 50amp cut 50 dual voltage 110220v cutting machine. The plasma cutting arc is especially sensitive to moisture. Plasma arc cutter equipment schematic diagram plasma arc equipment controls. In plasma cutting, the gas in the nozzle is ionised and focused by the special design of the nozzle. The plasma arc process has always been seen as an alternative to the oxyfuel process. Called pam, this is a method of cutting metal with a plasma arc, or tungsten inertgas arc, torch. The plasma arc welding and cutting process was invented by robert m. Plasma cutting is often used in fabrication shops, automotive repair and restoration, industrial construction, and.
Since plasma cutters produce a very hot and very localised cone for cutting, they are very useful for cutting and welding sheets in curved or angled shapes. After a few seconds of air flow you should see an arc form. Plans help guide us through the steps in the project, and, in many cases, they come with two very useful things. However, as with any piece of equipment you need to know how and why it does what it does and the necessary precautions to do the job safely. Esab invented plasma cutting in 1955, and weve never stopped developing ways to. This is because the holes in the swirl ring produce a swirl in the plasma jet. This complete cadcam program not only creates designs, it also runs the machine. The raw arc voltage cable carries this signal from the plasma cutter to the avhc controller. Introduction plasma arc machining pam employs a highvelocity jet of hightemperature gas to melt and displace material in its path.
Plasma cutting is an effective way to cut thin and thick materials. Works with common hand torch machine torch not needed. The only hard requirement is that the plasma cutter must not use a high frequency start mechanism in order to initiate the plasma arc. Slag resolidified parts of molten metal that adheres to the underside of the cut. The crossfire cnc plasma table was designed as a hobbylevel machine to accept a wide variety of available plasma cutters on the market today. Air compressors take humidified air from the atmosphere which always contains some amount of water.
The objective of this work is to study the effects of plasma arc cutting process parameters on hazheat affected zone and bevel angle for low carbon steel 1010 material with thickness 4 mm, which. Plasma cutting was developed in the 1950s to cut metals that could not be fired e. A opportunity to strive to offer a product for a economical price but also be able to provide a great quality machine. Plasma swirls as it exits the tip, biting one side and finishing off on the other. Working principle of pam in the plasma arc machining process, the material is removed by directing a highvelocity jet of high temperature 1c to 28,000c ionized gas on the workpiece. All torches need three ingredients to produce a pilot arc plasma gas, dc power, ac high frequency. The finish side of the plasma cut is the right side of the cut when facing the direction of travel. Plasma arc cutting system operator manual 803980 revision 1 powermax380. Those sections are power control, high current dc, low voltage dc and high voltage arc start. Plasma arc cutting system service manual 804470 revision 2. A plasma cutter will use this electrically conductive gas to transfer energy from a power supply to any conductive material, resulting in a cleaner, faster cutting process than with oxyfuel. Plasma arc machining process, diagram, advantages and. Human mechanics makes it easier to pull a torch than to push it. Designed specifically for plasma cutting, the plasmacam software is included with the machine.
A plasma cut leaves a beveled edge and a straight edge. Vicon is the industry leader in plasma cutting machines, coil lines, and hvac ductwork machinery. An electric arc generated from the external power supply is then introduced to this high pressured gas flow, resulting in what is commonly referred to as a plasma jet. With plasma, the machine can achieve part accuracies as high as 0. The plasma arc formation begins when a gas such as oxygen, nitrogen, argon, or even shop air is forced through a small nozzle orifice inside the torch. Check out our machine software demo video and click the link below to learn more. The plasma arc cutting process is illustrated in fig. Arc voltage torchtowork distance cutting speed initial pierce height pierce delay time plasma shield plasma shield plasma shield mm volts mm mmm mm factor % seconds o 2 o 2 78 17 94 17 0. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure. Shielding should be electrically continuous throughout its length. Section 2 introduction to plasma cutting plasma cutting basics what is a plasma. Power source control unit, plasma arc cutting torch with torch cable, work piece lead and lead assembly, plasma, shielding and cooling gases and gas control components what items are included in plasma arc cutting equipment. The approximate amperage of this type of plasma arc is 1220k amps per square inch.
The job of the avhc controller is to maintain a constant torch height or arc length over the material being cut, because that provides uniform quality cutting. Chapter 1 early plasma cutting the plasmaarc cutting process saw its first commercial application in the early 1960s. It is with pride that we can say that every machine produced is 100%. Plasmaarc cutting pac engineering flashcards quizlet. Dual voltage 110220v cutting machine zeny plasma cutting machine features the latest technology, it is perfect for the processing of metal materials machinery. If the swirl is reversed direction cw to ccw, the square side will switch. Aug 21, 2019 a cutting speed chart showing the rated cutting speed for the power source for mild steel, aluminum and stainless steel of various thicknesses. Mechanical components every machine has quite a few moving parts. Software and human interfaces that were designed specifically for plasma cutting tend to be much easier to learn and to use.
Only with this hot plasma stream materials such as plastics without transferred arc can be cut. So far i have only used the plasma cutting and arc welding feature and both work great. Investigation analysis of plasma arc cutting parameters on. Plasma cutting is used in cutting and gouging applications, and requires compressed air and electricity to create plasma gas. The key difference from gtaw is that in paw, by positioning the electrode within the body of the torch, the plasma arc can be separated from the shielding gas envelope. Wide plasma cutting torch compatibility with a simple, easytoinstall interface. The xpr series plasmas represent hypertherms most significant advance in mechanized plasma cutting technology ever and its now available on all arc cut pro machines in single and dual plasma configurations. Called pam, this is a method of cutting metal with a plasmaarc, or tungsten inertgasarc, torch. There are lots of other considerations that i will address later, such as swirling gases, kerf, height control, arc starting, shield gas, etc. So those are some of the basics of plasma cutting an arc carried in a stream of gas from an electrode through an orifice and then into the conductive metal that is being cut. Cutting grate precisely aligns to the frame, with stops that perfectly position material for indexing and utilizing sheet edges in long parts. Although plasma can cut through painted metal, it does require a solid connection on a clean part of the workpiece as close as practical to the work.
Plasma cutting is a process that cuts through electrically conductive materials by means of an accelerated jet of hot plasma. My board layout diagram is the most valuable piece in the building, repairing, and modifying process of my cutter. If the plasma gas is not swirled, results would be a bevel on both sides of the cut. In this study 12 mm plate thickness hardox400 has been cut by high tolerance voltage, cutting speed, and plasma gas flow rate included as main parameters in the analysis and their effect on unevenness of cut surface is evaluated. A highvelocity jet flow of hot ionized gas melts the metal and then removes the molten material to form a kerf. One example was the spray coating of the turbine blades of. Plasma arc cutting uses the plasma as an electrode to transfer an electrical arc to the work piece. Putting together a plasma cutting system the fabricator. En50199 en50192 plasma arc cutting system operator manual 802900 rev. The basic arrangement for a plasma arc cutting torch, similar to the plasma arc welding torch, is shown in figure 1071. It will also lead to a decrease in the service life of the relevant components of the control system and. Plasma is a gas heated to an extremely high temperature and ionized so that it becomes electrically conductive. Plasma arc cutting process and equipment considerations.
Plasma arc cutting pac is a thermal cutting process that makes use of a constricted jet of hightemperature plasma gas to melt and separate cut metal. The plasma arc cutting process cuts metal by melting a section of metal with a constricted arc. Improving manual plasma cutting quality the fabricator. Plasma arc instability may lead to uneven incision, builtup edge accumulation etc. Consequently, common applications for pac consisted of repeating cutting patterns in a massproduction mode. View and download hypertherm max43 instruction manual online. The plasma arc machining process is used for cutting alloy steels, stainless steel, cast iron, copper, nickel, titanium, and aluminum, etc. The heat of the arc melts the work piece and the force of the plasma and shield gases blow away the molten metal to cut the work piece. Every vicon plasma cutting table and machine shipped by plasma automation and vicon machinery is backed by professionals with over 40 years in the machine tool industry. Special offers get information on the latest offers. It determines the torch height by measuring the voltage used to maintain the arc. In this video ill show you the unitin and out, and how i tested various components to discover.
Control consoles for pac may contain solenoid valves to turn gases and cooling water on and off. Jul 01, 2009 the first part of this article and associated video dives right into the basic mechanics of good plasma cutting. Plasmacam cutting systems, cnc plasma cutting machine, cnc. Introduction plasmaarc machining pam employs a highvelocity jet of hightemperature gas to melt and displace material in its path.
Service manual pn 804470 revision 2 june, 2003 hypertherm, inc. Zeny dc inverter plasma cutter 50amp cut50 dual voltage. Learn vocabulary, terms, and more with flashcards, games, and other study tools. The cutter is listed at cutting up to 12 metal but have successfully cut up to 34 easily see pictures. Plasma cutting is the fastest cutting process on carbon steel, aluminum, or stainless steel. Early plasma cutters were large, slow, and expensive. Conventional plasma systems typically use shop air as the plasma gas, and the shape of the plasma arc is basically defined by the orifice of the nozzle. Plasma cutting is typically easier for the novice to master, and on thinner materials, plasma cutting is much faster than oxyfuel cutting. When a solid is heated, the molecules start to vibrate more vigorously. The principle of plasma arc machining is shown in the figure. It was also capable of spray coating hardening metals onto other metals. Plasma cutter works like a charm on steel and aluminum, sure beats firing up the cutting torches or replacing cutting discs on my grinder. Dec, 2018 i thought id make a quick video about the arduino based cnc plasma cutter that i made in the farm workshop.
Plasma cutter troubleshooting tip and tricks to help. However, for heavy sections of steel 1 inch and greater, oxyfuel is still preferred since oxyfuel is typically faster and, for heavier plate applications, very high capacity power supplies are required for. They usually have flowmeters for the various types of cutting gases used and a water flow switch to stop the operation if cooling water flow falls below a safe limit. In plasma cutting, is formed when an electric arc heats and ionizes a stream of highpressure gas. Understanding the basics of plasma arc cutting and plasma arc gouging will help welding operators be more successful with these techniques. Plasma cutting can be combined with waterjet or oxy fuel on the same part. In a plasma torch, known as the gun or plasmatron, a volume of gas such as h2, n2, 02, etc. Includes specialized plasmacam design and control software. Plasma arc welding paw is an arc welding process similar to gas tungsten arc welding gtaw. Miller plasma cutters can cut up to 78inch steel and stainless steel material, and up to 58inch aluminum material. Cut direction must be considered when programming the plasma cutter. It is suitable for a wide range of applications including sheet metal fabrication, light industrial use, site work, automotive, ducting work, repair and maintenance services. Amico power apc50, 50 amp plasma cutter, 115volt230volt dual voltage compact metal cutting machine, 34 in.
Adding heat to material causes the molecules in it to vibrate or move more quickly. Em interference was a major issue however, to overcome this i. The arc stability of nc plasma cutting machine directly affects the cutting quality. The process was unique in that it could achieve precision cutting and welding on both thin and thick metals. In this part of the series the process fundamentals are described with emphasis being placed on the operating features and the advantages of the many process variants. The second portion of the article and part 2 of the video provides guidelines for plasma cutting safety, proper equipment set up and shows you some cool accessories that make cutting easier. Plasma cutting function, advantages and disadvantages. The torch produces a highvelocity jet of hightemperature ionized gas called plasma that cuts by melting and. Plasma cutter industrial plasma cutters for sale in.
Zeny dc inverter plasma cutter 50amp cut50 dual voltage 110. Plasma cutting can be use for precision cutting on gauge material up to 6 thick stainless. By swirling the gas, the arc is distributed evenly along one side of the cut. With unmatched cut quality on mild steel, stainless steel and aluminum, the new xpr series plasmas increase cut speed and dramatically improve productivity while reducing operating costs. The arc cut pro series plasma table controller includes two extremely powerful plate nesting and cutting programs to give you all the tools needed to maximize productivity and efficiency. The superheated plasma jet is focused through a constricted orifice or tip, which directs the arc to the work piece. It is mostly used for the metals that cannot be cut by an oxyacetylene torch. Jun 18, 2018 basically, plasma arc machining pam is a metal cutting process where metals are cut with plasma arc, tungsteninertgas arc or a torch. The electric arc is formed between an electrode which is usually but not always made of sintered tungsten and the workpiece. Plasma arc welding is a substitute of tig arc process, offering greater welding speed and better weld quality, for welding thin metal section current at 0. We are a small company so we are able to talk to our customers one on one, we feel this is the proper way to do business. Mar, 2007 because the arc trails at an angle, at the end of a cut, slow your cutting speed and angle the torch into the cut through the last bit of metal. Hand torches can usually cut up to 38 mm thick steel sheet, stronger computer controlled torches can cut up to 150 mm thick steel sheet.