Journal of applied engineering science 1220144, 304 295 figure 9. The focus on this project is to obtain an optimum condition setting to obtain maximum mrr and minimum the surface roughness sr. The plasma arc cutting process employs a meltandblow cutting method, which heats, melts and vaporizes a localized area of the workpiece. Limited commercial use of the expensive plasmaarc cutting technology in the early 1960s eventually gave way to popu. Plasma arc machining pam plasma arc machining is a nontraditional thermal process. Pdf optimization of process parameters in plasma arc. 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. Focus is on the metal cutting process at the inside surface of the kerf. In simplest terms, plasma cutting is a process that uses a high velocity jet of ionized gas that is delivered from a constricting orifice. The the plasma arc welding paw and cutting process was invented by robert m. It can be used in many applications, including stack and shape cutting.
Plasma arc may be used for either cutting or welding and is the most widely used thermal process for cutting of aluminium alloys in manual, mechanised or fully automated modes fig. Cut charts the following cut charts show the consumable parts, cutting speeds and the gas and torch settings required for each process. Optimization of process parameters in plasma arc cutting of en 31 steel based on mrr and multiple roughness characteristics using grey relational analysis. Arc cutting processes plasma arc cutting pac a plasma a superheated, electrically ionized gas primary gas. This turns the inert gas to a plasma arc hot enough to melt the material being cut. Plasma cutting can be use for precision cutting on gauge material up to 6 thick stainless. It is also capable of spray coating hardening metal on other metals. The topic for the thesis writing is the analysis of process parameters of plasma arc cutting using design of experiment techniques. The plasma is a gaseous mixture of positive ions, electrons and neutral gas molecules. 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.
Plasma arc welding is an arc welding process similar to gas tungsten arc welding gtaw. The plasma arc is formed between a negatively charged electrode inside the torch and a positively charged workpiece. The high velocity ionized gas, that is, the plasma, conducts electricity from the torch of the plasma cutter to the work piece. 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.
Esabs latest innovations in the plasma cutting process automation increase production with more consistent cut quality every time. Numerical modeling of the metal cutting process in the. The metal shieldedgas welding is limited to the metal inertgas welding process. The arc is created by ionizing a gas plasma gas and then blowing the ionized plasma towards the surface of the workpiece in order to form a conductive pathway down which the main plasma current passes. The metal to be cut or removed is melted by the heat of. Plasma arc cutting process aristidis tsiolikas1, john kechagias2, konstantinos salonitis 3 p fig. Pdf the plasma arc cutting pac process was developed for difficultto machine materials in order to overcome the inefficiency and. A plasma power supply includes a user selectable control. Plasma cutting function, advantages and disadvantages. Pac is a thermal cutting process that uses a constricted jet of hightemperature plasma gas to melt and separate metal. Plasma arc cutting an overview sciencedirect topics. A brief overview of plasma cutting plasma arc cutting was developed 20 years ago primarily for cutting stainless steel and aluminum. A highvelocity jet flow of hot ionized gas melts the metal and then removes the molten material to form a kerf. Plasma and the plasma arc cutting process uses heated gas to cut through metal 30,000.
A person doesnt need to be a physicist or chemist to understand the plasma arc. The user selectable control enables selection of a single cutting persona that establishes at least a current, a gas pressure or gas flow rate, and an operational mode of the plasma arc cutting system. Nontraditional processes ntp nontraditional cutting. Esab invented plasma cutting in 1955, and weve never stopped developing ways to make plasma cutters better and easier. Pdf experimental investigation of the plasma arc cutting. Plasma arc welding plasma arc welding is the welding process utilizing heat generated by a constricted arc struck between a tungsten nonconsumable electrode and either the work piece transferred arc process or water cooled constricting nozzle nontransferred arc process.
Early plasma cutters were large, slow, and expensive. Plasma arc cutting uses an electrical arc formed from the nozzle to the surface being cut. Plasma arc cutting pac is a widely used industrial process for the cutting of different types of metals in several operating conditions. Although favorable economically, mild steel was seldom cut with this process because of three fundamental limitations. Plasma arc cutting is the process in which the metal is cut by melting a localized area with a constricted arc and removing the molten material with a high velocity jet of hot, ionized gas. Plasma cutting can be combined with waterjet or oxy fuel on the same part.
Power source the power source required for the plasma arc process must have a. Plasma arc welding process principle, main parts, working. Basics of plasma arc cutting vs oxyfuel cutting grainger. Arc rays from the cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin. Near the tip of the plasma jet, the hydrogen and oxygen recombine, affording heat. Plasma cutting is the fastest cutting process on carbon steel, aluminum, or stainless steel. Turn the plasma arc cutter on and adjust the amperage the manufacturers specifications for the thickness of metal to be cut. Typical materials that can be cut with a plasma torch are steel, stainless steel, aluminium, brass, copper and other conductive metals. The plasma welding consists only of the plasmaarc welding process which works with a transferred arc. Parts, working principle, advantages, application and more. Thus, unlike the oxyfuel process, the plasma process can be applied to cutting metals which form refractory oxides such as stainless steel, aluminium, cast iron and nonferrous alloys.
This process is based on an electrical arc between an electrode inside a torch and the workpiece. The process of cutting metal with a plasma arc cutting tool is investigated and discussed. Explain plasma arc cutting processes and identify related safety. In thesis work literature has been studied in context to parametric optimization of. In the latter case cuts of excellent quality can be achieved in material of up to 250 mm thickness at high cutting speeds. At praxair, well work with you to understand your cutting and welding needs and help you choose the most effective and economical cutting process for your operations. Plasma arc cutting pac is a nonconventional manufacturing process capable of processing a variety of electrically conducting materials.
Bevel angle dependency of the cutting speed, material thickness s6 mm, cutting current i45 a and i80 a figure 10 shows the kerf width, surface rough. The process works by heating gas to temperatures that cause it. The plasma cutting process is investigated experimentally in the present paper for assessing the quality of the cut. The cutting head is programmed to the contour of the part, including complex shapes. Plasma arc welding paw is a arc welding process using heat produced by a compressed arc between a tungsten nonconsumable electrode and another workpiece transferred arc process or watercooled constricting nozzle nontransferred arc process. The plasma arc welding and cutting process was invented by robert m. Plasma cutting is a process in which electrically conductive materials are cut through by means of an accelerated jet of hot plasma. For additional safety precautions, process instructions, and system troubleshooting. To activate the plasma arc cutter make sure the air pressure is sufficiently around 70 p.
Plasma arc cutting process and equipment considerations twi. Identify the different components of plasma arc cutting equipment and ppe. The plasma cutting process, as used in the cutting of electrically conductive metals, utilizes this electrically conductive gas to transfer energy from an electrical power source through a plasma cutter torch to the material being cut. Plasma is a gaseous mixture of positive ions, electrons and neutral. Plasma and the plasma arc cutting process uses heated gas to cut through metal 30,000 degrees fahrenheit.
The basic plasma arc cutting system consists of a power supply, an arc starting circuit and a torch. This is an important region that is not well documented due to the difficulty of experiments and the complexity of computation needed to characterize this process. The basic arrangement for a plasma arc cutting torch, similar to the plasma arc welding torch, is shown in figure 1071. Chapter 1 early plasma cutting the plasma arc cutting process saw its first commercial application in the early 1960s. 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. Plasma arc cutting, also referred to as plasma fusion cutting or plasma cutting, is a fabrication process which employs superheated, ionized gas funneled through a plasma torch to heat, melt and, ultimately, cut electrically conductive material into. Wear face protection helmet or shield with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when cutting. Describe the plasma arc cutting process and its applications in the pipefitting trade. The operator should position himselfherself so there will be minimum exposure o fumes during the cutting process. Plasma arc cutting is based on the establishment of a direct current arc between a tungsten electrode and the surface of a conducting metal. Plasma cutting services for high quality metal components. As the plasma strikes the workpieces surface, the workpiece material absorbs the thermal energy of the arc and plasma gas, increasing the internal energy and generating heat.
The cuts are made by a high temperature, high velocity gas jet generated by constricting an arc between a. The numbers shown in the cut charts are recommended to provide highquality cuts with minimal dross. Since the plasma arc cutting process is capable of handheld or machine torch cutting, metals ranging from thin gauge aluminum to 1 12inch carbon or stainless steel can be plasma cut. The plasma arc cutting and gouging processes use plasma to transfer an electrical arc to the work piece. The plasma cutting process is described covering process characteristics, power source, cut edge quality and process variants dual gas, water injection, water. This process was unique because it could do precision cutting on both thick and thin metal. Water introduced to a plasma jet near its base dissociates into hydrogen and oxygen, adding material and force to the jet and tending to make it more straightsided and stable.
A plasma arc cutting machine cutting the internal sections of a metal part. With a power source, plasma torch, compressed air, electrical power, and a supply of tips and electrodes, plasma arc cutting machines can rapidly and precisely cut through, gouge, or pierce any electrically conductive metal without preheating and with a minimal heataffected zone. Power source the power source required for the plasma arc process must have a drooping characteristic and a high voltage. Plasma is defined as a gas that has been heated to a sufficiently high temperature to become partially ionized and therefore electrically conductive. Typical materials cut with a plasma torch include steel, stainless steel, aluminum, brass and copper, although other conductive metals may be cut as well. Plasma arc cutting uses a jet of plasma that can reach as high as. Pdf the plasma arc cutting pac process was developed for difficulttomachine materials in order to overcome the inefficiency and. The cuts are made by a high temperature, high velocity gas jet generated by constricting an arc between a tungsten electrode and the component. 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. Consequently, common applications for pac consisted of repeating cutting patterns in a massproduction mode. A gas such as argon, nitrogen, hydrogen or air is injected into the arc inside the torch, turning it into a plasma with a temperature of more than 10.
The plasma cutting machine adds electricity which forms a circuit with the metal to be cut. The term plasma, as employed in physics, means ionized particles. When a pilot arc is used in the transfer process a low voltage, low current, high frequency arc is established between the electrode and the torch nozzle inside the torch. Welding revo technologies and enterprisesan iso 9001.
Plasma cutting is a process that cuts through electrically conductive materials by means of an accelerated jet of hot 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. The plasma arc cutting process cuts metal by melting a section of metal with a constricted arc. Plasma arc cutting process and equipment considerations. Pdf developments in plasma arc cutting pac of steel alloys. Materials difficult to cut with a torch using known methods, such as inchthick plates of stainless steel or highspeed tool steel, may. The superheated plasma jet is focused through a constricted orifice or tip, which directs the arc to the work piece. The invention features methods and apparatuses for establishing operational settings of a plasma arc cutting system.
See below for some of the differences and advantages of. Since last many years, the precise and accurate machining technology of hard metals ferrous, nonferrous and. Dr andela lazarevic experimental research of the plasma arc cutting process. A gas such as argon, nitrogen, hydrogen or air is injected into. Cut flat metal sheets and plates by melting high productivity air carbon arc cutting arc. On this channel you can get education and knowledge for general issues and topics. To understand plasma arc gouging better, its helpful to understand plasma arc cutting pac. Another very common thermal cutting technique is plasma arc cutting. Study 15 terms plasma arc cutting flashcards quizlet. The process employs two inert gases, one forms the arc plasma and the second shields the arc plasma.