Accurate Plasma Cutting Requires the Right Plasma Cutter

A high-precision, solid, heavy-duty CNC Plasma Cutter starts with a design that is created specifically to be the most stable platform possible for accurate plasma cutting. By building a plasma cutter with accuracy, stability, speed and durability as a goal, you will end up with a machine that will outperform and outlast it's competition.

Does heavy-duty or fully-welded really matter? Is accuracy over the lifetime of the machine important? Yes! When the base of the machine does not move during the cutting process, the plasma torch is able to deliver incredible accuracy. This is accomplished by starting with a super solid, fully welded base. Bottom line - You need professional grade machinery to produce professional grade products.

The components that make up a highly accurate, heavy-duty plasma cutter need to be designed to work as a unit. Mismatched components may make for a lower cost machine, but the cut quality will suffer. Matched components eliminate repeated set-up adjustments that slip or wear over time, especially under heavy use.

Pairing a heavy-duty cutting table with precision machined components and state-of-the-art software, results in a CNC plasma cutter that is capable of amazing precision. Adding a properly matched plasma torch system provides very high cut quality to any shop. This means accurately cut parts with crisp, smooth edges, eliminating the need for secondary operations that add additional time and cost to each and every project.

The plasma torch, the business end of the cutter, also requires special consideration. It will need to be matched to your applications. Tight integration of the torch and controls with the software will provide high productivity and reliability. All must be present to realize the full potential of a top quality, highly accurate plasma cutter.

The CNC software package needs to be state-of-the-art. It will need to be easy to use, easy to configure and flexible. By having the latest automation features, it will be able to provide the high productivity and reliability you are looking for. Automatic true shape nesting software is another key component that will allow the full potential of a top-quality plasma cutter to be realized.

Whether you are involved in shape cutting, metal fabrication, or metal working, a heavy duty, a fully unitized plasma cutter is your best choice.

It will enable you to cut with maximum efficiency. Plasma cutting machines must be able to hold their advertised tolerances today and, more importantly, for many years to come. Only a well designed and well built plasma cutter will do this for you.

Even in slow economic times, it can be a mistake to be penny wise and pound foolish. Can you afford to buy cheap? Buying quality is never a mistake.

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Affordable CNC Plasma & Laser Cutting Machine

The plasma cutting process uses high velocity as well as high temperature ionized gas along with an arc, to cut different types of materials.

Plasma cutting process

The plasma cutter torch has a high velocity ionized gas that conducts electricity, which is used to heat the work piece and eventually melts the material. While the purpose of the arc is to melt the material with its high heat, the function of the gas is to blow the molten material away from the piece and cut the material. Due to the force of the plasma, you get a clean cut with very little or no slag at all. The plasma arc roughly has a speed of up to 20,000 feet per second (that's more than 13,000 miles per hour!) while the temperature is as high as 30,000º F.

Different types of Plasma cutting machines

Plasma cutting machines are available in a variety of types such as plasma torches, plasma torches, and plasma cutters. Compressed air or nitrogen is used as a cutting gas in plasma cutting torches. The torches have a narrow-width kerf along with a water-cooled electrode. Plasma torches use a high temperature gas steam, which is produced by passing the gas through an electric arc discharge. The plasma torch has two electrodes that are metallic and tubular in nature. The electrical arc flows between the negative or positive electrodes. Plasma cutters are specially used for cutting steel and materials that conduct electricity.

Advantages of Plasma cutting machines

- They provide high quality cuts and fast travel speeds.

- It is a low cost process for short runs as no physical tooling is required.

- A cost effective option for thick metal sheets.

- As compared to laser cutting can cut thicker sheets.

- It can be used to cut a wide variety of geometric shapes along with 2D shapes that do not require too much precision.

Specifications

The process can be used on ferrous and non-ferrous metals and requires only software tooling. It helps to reduce cost by reducing total cut length. At times, some warping may occur on complex parts. The cut edge is somewhat roughened and may show the presence of an oxide layer. Further, the plasma cut surface may not be precisely perpendicular to the surface of sheet material.

eMachineShop offers you information about various types of CNC machines along with other cutting techniques such as Plasma cutting and Laser cutting. Visit the site http://www.eMachineShop.com to design and order custom plasma cut parts today!

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Plasma Cutter Consumables - Regular Maintenance & Correct Parts Will Help to Lower Productions Costs

The parts that make up your plasma torch must be inspected regularly and replaced when warranted to keep your plasma cutter safe, working cost effectively, and able to perform the highest cut quality. Using the correct and matching torch parts will make all the difference in cut quality and consumable life.

As the nozzle at the cutter's tip concentrates the gas and introduces a spark from the electrode, it turns the gas stream into plasma. Inert or semi-inert gases are used to shield the area where the plasma touches the metal. The force of the plasma is strong enough to blow the molten metal out of the cut. The plasma itself reaches temperatures as high as 30,000 degrees Fahrenheit. This kind of temperature and force takes its toll on the cutter's tip and components.

The most common plasma torch wear items are: the Electrode, the Nozzle, and the Shield. The Swirl Ring will last several changes longer when properly maintained.

The Electrode:

The primary function of the electrode is to provide power to the plasma arc. Electrode wear is detected by examining the insert and measuring pit depth. Excessive electrode wear reduces cut quality and can result in damage to the plasma torch. Premature electrode wear is most often caused by a few common culprits, the most common being mismatched torch parts. Other contributors may include incorrect gas flow settings, gas leaks, moisture build-up and impurities in the plasma gas.

The Nozzle:

The nozzle limits the plasma arc to a specific diameter through a perfectly round hole in its' tip. It constricts the plasma gas, increasing its' velocity. The most common cause of nozzle damage is, once again, mismatched torch parts. Also, incorrect cut distance, cutting material thicker than the capability of your plasma cutter, and incorrect gas and amperage settings will cause premature wear. Vigilance on the part of the operator, regular inspections and using OEM parts will help extend the life of your plasma consumables. The electrode and nozzle should be changed as a set to keep cut quality at its very highest.

The Shield:

The shield surrounds the consumable stack, protecting the parts from damage. It contains an identical, perfectly round hole as the Nozzle. The most common problem associated with the shield is damage to the main orifice due to being blocked or clogged by dross or spatter. Dross can be usually be picked off. If the main orifice is out-of-round, it must be replaced.

The Swirl Ring:

The swirl ring creates and controls the swirling action of the gas as it flows around the electrode and nozzle. When inspected and cleaned regularly, the swirl rings will outlast many electrode and nozzle changes. A clogged swirl ring will hamper gas flow, decrease cut quality and shorten electrode and nozzle life. Make sure you match the appropriate swirl ring to the other plasma consumables in your torch.

Regular examination and care of all of the plasma torch parts will help to maximize the service life, efficiency and performance of your plasma cutter. Regular maintenance and replacement of worn consumable parts will help to keep your cut quality high, reduce scrap cost, reduce down-time, and lower your production costs.

Using genuine OEM consumable parts and accessories and matching them for your plasma cutter and application is the only way to ensure optimal performance and to maintain the highest cut quality. A low initial consumable cost is usually more expensive in the long run. Mismatched plasma consumables will result in shorter consumable life and reduced cut quality. Your plasma cutter's manual will specify the correct parts for various consumable configurations.

To achieve the highest cut quality and consistency, inspect regularly and use only genuine, matching consumables that are manufactured to the highest standards.

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Plasma Cutters Can Cut Though Anything!

One of the best tools for cutting metal is a plasma cutter. It is effective and convenient to use, and thanks to the latest technology being applied in the area, it is now possible to cut metal with almost laser precision.

A plasma cutter works differently than a conventional welding torch. Rather than using a flame produced from a burning gas in the style of oxy acetylene welding, a plasma cutter uses a jet of inert gas such as compressed air, and then applies a very high voltage charge. The electric charge arcs through the jet of air, and ionizes the gas. The ionized gas reaches extremely high temperature, and becomes what is called plasma.

This highly charged and hot temperature jet of plasma is able to melt through metal at the point of contact without having a massive impact on the surrounding material. This makes a plasma cutter a very precise way of cutting metal.

For small jobs in a workshop where metal is being cut in order to make a bodywork patch, or a replacement panel, plasma cutters are the ideal solution. One of the most important aspects of plasma cutters is that they use an inert gas, meaning that you do not have to worry about storing volatile and explosive gases.

In the past, plasma cutters were a fairly imprecise and blunt means of cutting metal thanks to their large "flame", however, thanks to advances in the materials and technology used to manufacture plasma cutters, they are now able to produce a much more focused flame. This means that you not only get a more exact and neater cut, but are able to do it with lower power.

Plasma cutters are available from under $1000. You can get a Firepower 12 amp plasma cutter with its own compressor that uses compressed air to create the plasma torch for $998.75. This tool, which is ideal for small jobs in any work shop, is flexible enough to carry out a range of tasks.

With a basic compressor driven plasma cutter, you get a torch with two settings. The pilot arc of plasma is ideal for burning off paint, while when you turn up the power; the cutter is able to cut through sheets of steel an eighth of an inch thick at a rate of around nine inches per minute.

By spending a little more, it is possible to get a more powerful and flexible tool. For less than $1350, you can buy a Lincoln Electric Welders Century 25 Amp Plasma Cutter. This tool is designed for effective auto body repair jobs, and provides a fully earthed cutting arc that removes the high frequency harmonics that are able to damage the complex electronics in a car.

The century 25 amp plasma cutter has its own built in compressor, which has an adjustable regulator to control the size of the actual plasma. This means that you can vary the intensity of the cutting edge of the tool, and deal with metals of different thicknesses up to 3/16" of milled steel, at an acceptable cutting rate.

At the top end of the plasma cutter market there are complex and powerful tools such as the Miller Auto Arc 4500 Plasma Cutter. This tool, which retails from around $2500, is a much more flexible and powerful cutter than most other models. Its 27 amp power supply, coupled with a strong compressor means that it can deliver a flame hot enough to cut through steel more than half an inch thick at an acceptable rate, and get through most body panel metal like a hot knife through butter.

As with all tools, it is important to select the one that fits in best with your business needs and budget. If you only require a lightweight plasma cutter for occasional jobs in the workshop, then an entry level model is perfectly acceptable, however, if you need to perform regular work requiring the tool, then getting a more robust model is an excellent idea, as the tool will more than pay for itself over time thanks to its reliability and ability to cut through metal much faster and let you get on with work more quickly.

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