Plasma cutting is replacing oxyacetylene cutting in many applications with its speed and cost-effectiveness, especially with the price of plasma cutters dropping and the emergence of portable models, now is the time to seriously consider the application of plasma cutting technology in your cutting applications.
Table of contents
II. Determine the thickness of metal commonly used for plasma cutting
III. Determine the ideal cutting speed requirements for plasma cutting
IV. Start-up method of plasma cutting machine
V. Hidden costs of plasma cutting: consumables cost and life
VI. Plasma Cutting Field Testing and Selection
I. Plasma Cutting Technology
Plasma cutting uses a high-speed jet of ionized gas to cut. This ionized gas is called plasma. The arc of the plasma cutting gun conducts current into the workpiece, heating and melting the material, and then the high-speed jet blows away the molten metal to complete the cutting process. Compared with oxyacetylene cutting, plasma cutting can be used for any conductive metal, including aluminum, stainless steel, etc., while oxyacetylene cutting relies on oxidation and cannot cut materials such as aluminum and stainless steel.
II. Determine the thickness of metal commonly used for plasma cutting
Cutting requirements for 1/4-inch thick materials:
In general, if you often deal with metal materials 1/4 inch (about 6.35 mm) thick, you can consider choosing a low-amperage plasma cutter. Metals of this thickness can usually be effectively cut with lower power and current, such as machines in the 20 to 40 amp range. Such machines can provide stable cutting quality and speed, suitable for thinner metal sheet processing.
Cutting requirements for 1/2-inch thick materials:
For 1/2-inch (about 12.7 mm) thick metal materials, you need to choose a plasma cutting machine with higher power and current output. Usually, this thickness of metal requires a current of 50 amps or more to ensure fast and efficient cutting. High-powered machines can handle thicker metal plates and still maintain good cutting quality and accuracy when cutting at high speeds.
III. Determine the ideal cutting speed requirements for plasma cutting
Production plants and job shops have huge differences in cutting speed requirements. It is a good choice to choose a plasma cutting machine that can meet your normal cutting speed of twice the thickness.
Cutting speed requirements of production plants
- Industry differences: Production plants in different industries have different requirements for cutting speed. For example, the automotive manufacturing industry usually requires high-speed cutting to process large amounts of metal sheets, while the aerospace industry may require higher precision cutting speeds to ensure the quality and dimensional accuracy of parts.
- Mass production: Production plants often require a large number of continuous cutting, so it is important to choose a plasma cutting machine that can complete the task efficiently in a short time. Such machines usually have high power and fast-response cutting speeds, which can significantly improve production efficiency.
- Automation requirements: Some factories may use automated cutting systems, which require cutting speeds that can quickly adapt to various workpieces and thicknesses. Therefore, it is crucial to choose a machine with adjustable and stable cutting speeds to meet the requirements of automated production lines.
Cutting speed requirements for job shops
- Flexibility and diversity requirements: Job shops usually need to be flexible to deal with a variety of metal materials of different thicknesses and shapes. It is key to choose a machine that can quickly adjust the cutting speed and adapt to different workpiece requirements, so as to ensure high efficiency and high-quality cutting operations in different projects.
- Customized production: Some job shops may handle customized workpieces or small batch production, so a cutting machine that can be quickly set up and adjusted is needed to adapt to different customer needs and project requirements.
IV. Start-up method of plasma cutting machine
Most plasma cutting machines use high-frequency arc starting, which is easy to start but may cause interference to computers or office equipment. If your production environment involves sensitive PLC or PC control equipment, it is particularly important to choose an alternative startup method that can eliminate high-frequency interference.
Advantages and Disadvantages of High-Frequency Arc Starting
- How High-Frequency Arc Starting Works: Most plasma cutting machines use high-frequency arc starting technology to start the cutting process. This technology uses a high-frequency current to generate an arc, allowing the plasma cutting machine to start quickly and reliably. The advantages of high-frequency arc starting include easy starting, simple operation, and applicability to a variety of working environments.
- Possible interference problems: However, high-frequency arc starting may also cause interference to surrounding electronic equipment, especially for sensitive PLC (programmable logic controller) or PC (personal computer) control equipment. These devices may be interfered by high-frequency electromagnetic fields, causing their normal operation to be affected, or even damage to the equipment or data loss.
Choice of alternative starting methods
- DC arc starting technology: In order to solve the interference problem that high-frequency arc starting may cause, some modern plasma cutting machines use DC arc starting technology. This technology uses direct current to generate an arc between the electrode and the nozzle without the need for high-frequency electromagnetic waves. This can avoid interference with surrounding electronic equipment and ensure the normal operation of sensitive equipment in the production environment.
- Lift arc starting technology: Another common alternative starting method is lift arc starting technology. This technology starts the arc by establishing contact between the electrode and the workpiece, and then quickly moves the electrode to form a cutting arc. The lift arc starting technology not only avoids high-frequency interference, but is also safer and more controllable at startup, and is suitable for applications that require high-precision cutting or are sensitive to electromagnetic interference.
Choose the right starting method
When choosing a plasma cutting machine, you need to consider the sensitivity of your production environment to equipment interference:
If there are a large number of sensitive control devices in your operating environment, especially automated production lines that require long-term stable operation, it is recommended to choose a cutting machine model that can eliminate high-frequency interference, such as a machine using DC arc or lift arc starting technology.
For some working environments, high-frequency arc starting may not cause serious effects. You can choose a suitable starting method based on actual needs and equipment use environment.
V. Hidden costs of plasma cutting: consumables cost and life
Plasma cutting guns have a variety of consumables that need to be replaced regularly, such as retaining covers, nozzles, electrodes, etc. Choosing a cutting machine with fewer types of consumables can reduce the frequency and cost of replacement. Pay attention to comparing the consumable life data of different models.
Consumables types and replacement frequency
- The consumables of plasma cutting machines mainly include retaining covers, nozzles, electrodes and swirl rings. These consumables will gradually fail due to wear during the cutting process and need to be replaced regularly to ensure cutting quality and efficiency.
- Retaining cover: The retaining cover is an important part to protect the cutting gun and can extend the life of other consumables, such as nozzles and electrodes. Regular replacement of the retaining cover can avoid reduced cutting quality and equipment damage.
- Nozzle and electrode: The nozzle and electrode are the most frequently replaced parts in the plasma cutting process. The function of the nozzle is to guide the plasma jet, and the electrode is the conductor of the current. Their wear will affect the cutting quality and efficiency, so they need to be replaced regularly according to the frequency of use and the type of material.
- Swirl ring: The swirl ring is used in some cutting machine models. Its function is to improve the stability of the airflow and plasma jet, thereby improving the cutting quality and extending the life of other consumables.
Comparison of consumable life data
- Choosing a cutting machine with fewer consumables can significantly reduce the replacement frequency and cost. The consumable life data of cutting machines from different manufacturers may vary, and these data can usually be found in the product specification sheet or user manual.
- Consumable life standards: Manufacturers often evaluate the life of consumables based on different standards, such as the number of cuts or the number of starts. For continuously running production facilities, the consumable life may vary, so the economic and practicality of each model needs to be evaluated based on actual usage.
- Cost-effectiveness considerations: When selecting a cutting machine, in addition to considering the initial purchase cost, the frequency and cost of replacing consumables should also be considered comprehensively. Choosing a model with a long consumable life can effectively reduce operating costs and reduce downtime caused by changing consumables in production.
VI. Plasma Cutting Field Testing and Selection
Perform test cuts on multiple plasma cutting machines to compare the cut quality. Observe the dross at the bottom and the cut angle. Selecting a well-designed machine can provide a more compact and concentrated arc to ensure the cut quality.
Importance of Field Testing
- Cutting Quality Evaluation: Before selecting a plasma cutting machine, it is very important to conduct field testing. By performing cutting tests on multiple different models, their cut quality can be directly compared. Paying attention to the amount of dross (residue) at the bottom and the cut angle are key indicators for evaluating cut quality. Well-designed cutting machines generally provide a tighter, more focused arc, resulting in cleaner, more precise cuts.
- Arc Performance: Observing the arc performance of each cutting machine is also an important part of the testing process. A well-designed plasma cutting machine should be able to maintain a stable arc during the cutting process, ensuring the continuity and precision of the cutting.
Compare the advantages and disadvantages of different models
- Cutting Capacity: Compare the cutting capacity of different models based on the test results. Some models may perform better when processing specific materials or thicknesses, while other models may have advantages in cutting speed, accuracy, or stability.
- User-Friendliness: In addition to cutting quality, the ease of use of the machine and the comfort of the operator should also be considered. A well-designed machine usually takes the operator's experience into consideration, providing a simple and clear control panel and an ergonomic cutting handle.
Notes
- Environmental adaptability: When testing and selecting a plasma cutting machine, also consider the special requirements of the working environment. For example, if the cutting work requires moving the machine or operating in a confined space, it may be more appropriate to choose a lightweight and easy-to-move model.
- Consumables and Maintenance Costs: Finally, consider the consumables costs and maintenance requirements of the cutter. Choosing a machine with fewer and longer-lasting consumables can help reduce operating costs and production downtime caused by replacing consumables.
VII. Other Considerations
Consider the portability and durability of the cutter, especially for work environments that require mobile equipment. Choosing a machine with a small footprint and easy portability is especially important for work areas with limited space.
Portability and Mobility
- Work Environment Requirements: Choosing a plasma cutter with good portability is crucial in work environments that require frequent movement or limited space. Such machines are usually designed to be lightweight and easy to carry, allowing for easy movement and adjustment of positions within the work area.
- Small Footprint: For work areas with limited space, choosing a cutter with a small footprint can effectively utilize space resources while not occupying too much work space. This design also helps improve work efficiency and allows operators to have more freedom in work layout and equipment adjustments.
- Portability: Some plasma cutters are equipped with facilities that facilitate transportation, such as wheeled bases or shoulder straps. These designs make it easy for operators to move the equipment to where it is needed, whether moving between different work stations within the factory or quickly adjusting positions during field operations.
Durability and adaptability to the working environment
- Protective design: Consider choosing a cutting machine with a protective design that can effectively resist the impact of vibration, dust and other contaminants in the working environment. For example, some models may provide additional protective covers or casings to ensure that key internal components are protected from external influences.
- Durable materials: The casing and key components of the cutting machine should be made of durable materials that can withstand long-term use in harsh environmental conditions without being easily damaged or corroded. This design not only extends the service life of the equipment, but also reduces the frequency of repairs and replacement of parts.
User-friendliness and ease of operation
- Control panel design: Make sure the selected cutting machine has a clear and easy-to-read control panel that is easy to operate, even for operators with limited use experience. A well-designed control panel can reduce operating errors and improve work efficiency.
- Ergonomic design: For handheld equipment, the cutting gun should be ergonomically designed with a comfortable and easy-to-hold handle to reduce operator fatigue while promoting cleaner and more precise cutting results.
VIII.Conclusion
At the forefront of this plasma cutting space is China's premier machine manufacturer, KRRASS. With a commitment to quality, sustainability, and excellence, KRRASS is not only participating in the industry; it is leading it. Partner with us for a brighter future.
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