PLASMA CUTTING MACHINES

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Plasma Range

Plasma cutting has been around for many years. For many applications it remains as the most cost-effective method of cutting a range of materials.

Developments and enhancements to control, plasma and software systems have enabled significant improvements in cut quality and capability. Bolt ready holes can be cut without the need for any subsequent rework, and the edge quality even on the thicker materials is excellent with our plasma cutting machines.

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Kerf Plasmaster 3015

Plasmaster profile

Cutting Machine

Standard Cutting Size

1500mm by 3000mm
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Kerf RUR 2500 Profile Cutting Machine

RUR

Cutting Machine

Standard Table Size

1500mm, 2000mm, 2500mm and 3000mm wide
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Kerf RUM Profile Cutting Machine

RUM

Cutting Machine

Standard Table Size

2500mm, 3000mm, 3500mm and 4000mm wide.
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LOOKING FOR A CLEANER CUT?

Traditional plasma cutting is a very cost effective, tried and tested method of cut, but if you’re looking to cut thinner materials, or achieve higher cut speeds, Kerf High Definition Plasma is the solution for you.

Using Kerf’s high definition plasma machines we can achieve cut speeds of 3,300 mm/min on 12mm thick mild steel using one of our mid-range plasma cutters. The plasma cutting process can pierce and cut mild steel from 1mm right the way through to 55mm thick.

Developments and enhancements to control, plasma and software systems in plasma cutting machinery have enabled significant improvements in cut quality and capability. Bolt ready holes can be cut without the need for any subsequent rework, and the edge quality even on the thicker materials is excellent. High definition plasma cutting is ideal for mild steel, stainless and aluminum profile cutting.

Kerf offers ‘Best in Class’ high definition plasma cutting systems. We achieve this by selecting and recommending appropriate equipment from leading global suppliers. Based on your requirements, Kerf brings together a turnkey solution that meets your specification; this includes the machine, software systems, installation, training and post-sales support.

What is plasma cutting?

For many years plasma cutting has been a very cost-effective and flexible method of cutting mild steel, stainless steel, wear resistant plate and aluminium. The process itself can be used with a simple handheld cutting torch or more accurately when a torch is mounted on a CNC cutting table.

Materials ranging from 1mm through to 75mm mild steel can be cut with the plasma process and at relatively high speeds. There are currently three levels of plasma that Kerf Developments offer. These are:

plasmA CUTTING TECHNIQUES

Compressed air plasma

This is the entry level into automated plasma cutting. The profiles and internal holes and profiles will have a draft angle. On thinner profiles this might not be an issue. On thicker structural parts that are possibly being welded then they will possibly require rework to remove the bevel and dross on the bottom face of the profiles. With this style of system holes may require additional drilling operations for use structural applications.

Ideal applications for this include thinner applications with material up to 5mm although the process itself can be used for cutting 20mm with a Lincoln Electric Flexcut 125amp plasma. Bevel on the part is caused by the motion of the plasma gas as it is emitted from the nozzle. In standard compressed air plasma cutting systems this is unavoidable.

High Definition Plasma

For this type of system, the plasma arc is controlled more giving an improvement in cut quality. The process generates better edge quality with less bevel on the edge and with an improvement in hole and slot quality. There may be some light dross on the lower face, however, this can normally be removed with a manual scraper. This type of plasma unit will cut parts faster and with less post cut rework.

High-definition systems can pierce and cut up to 50mm mild steel if required using a high-powered system. With an edge start a 400amp system could cut 75mm mild steel! The plasma units can be fitted with either a manual gas console where the operator sets the power and gas power pressures and flow rates or with fully automatic gas consoles.

High definition with UltraSharp

UltraSharp takes the benefits of high-definition plasma and an automatic gas console to provide the best possible cut quality. It is the automatic gas console that is key to the process as it enables changes to be made to gas pressures and flow rates without any manual intervention. As a result for smaller holes and slots the machine can automatically slow the cut speed to ensure that we maintain the best possible shape to the plasma arc with no lag on the profile.

This is an automatic process that requires no manual intervention from the operator helping to de-skill the process for the machine operator and ensure consistently high cut quality. The result is what Lincoln Electric describe as “Bolt Ready Holes”. This style of system offers the best cut quality and longest consumable life. It also allows you to cut more consistently at faster speeds.

Plasma Consumable Life vs Cut Quality

Plasma torch consumable life is a complex subject and one that cannot be addressed simply. There are many variables that affect the life of torch consumables. Because each application is unique and represents different operating conditions, it is difficult to make blanket statements that suit every situation.

Rather than attempting to note specific numbers for every possible combination of applications, we would like to make the following broad statements to clarify what might be expected with Lincoln Electric high current density plasma cutting systems:

When discussing torch consumable life, Lincoln Electric typically refers to electrode life, not a combination of electrode, nozzle, swirl ring, shield cap and other typical front end parts. In most applications an electrode will typically outlast a nozzle by a ratio of 2:1. Shield Caps will typically last as long as two electrodes. Inner Retaining Caps and Swirl Rings will typically last as long as ten electrodes. Outer Retaining Caps are rarely consumed.

Assuming proper system operation, the three most important factors that determine the life of an electrode are amperage, number of pierces, and cut duration.

Cut errors such as mis-firing above the plate or running out of material before the arc is properly extinguished will severely diminish electrode and nozzle life. Improper piercing height can cause poor shield cap life. Torch consumables can be quickly ruined if the torch crashes during operation. Gas quality is extremely important, dirty, moist, or oil contaminated air will rapidly deteriorate consumables.

Under ideal cutting conditions the following electrode life could be achieved.

Assuming proper system operation, the three most important factors that determine the life of an electrode are amperage, number of pierces, and cut duration.

Cut errors such as mis-firing above the plate or running out of material before the arc is properly extinguished will severely diminish electrode and nozzle life. Improper piercing height can cause poor shield cap life. Torch consumables can be quickly ruined if the torch crashes during operation. Gas quality is extremely important, dirty, moist, or oil contaminated air will rapidly deteriorate consumables.

Under ideal cutting conditions the following electrode life could be achieved.

Consumable life cannot and the number of pierces that can be achieved cannot be considered in isolation. Cut quality will deteriorate as the consumable wear.

Genuine Lincoln Electric consumables are manufactured to the highest standards and utilise Hafnium Optimization Technology in the manufacture of the electrodes.  This along with the unique electrode cooling design extends useable electrode life considerably meaning more production from a single set of consumables thereby contributing to a lower cost of operation.

Plasma Machine Consumable Life and Cut Quality

Parts cut with Lincoln Electric FineLine™ High Definition Technology with the Spirit II systems will have an edge bevel of 2 degrees or less from top to bottom. This is historically the industry standard for precision plasma cutting.

Certain competitor’s consumable life statements now accept cut edge bevels of 3.18° to 6.33° (4° average). Bevels in the 3-6° range are normally considered conventional plasma.  On thinner materials the impact of this level of bevel on product quality, however, on thicker materials this can result in considerable rework to bring the cut component back within manufacturing tolerance.

Torch consumable life is a very visible indicator of operating expense but cutting speed and elimination of secondary processing to compensate for poor cut quality are of far more importance when calculating operating costs. Lincoln Electric high current density plasma cutting systems offer a unique combination of cut quality and speed that ensure the lowest cost of producing cut parts.

Cut quality needs to be considered over the entire life of the consumables.

GET IN TOUCH TODAY

Our sales and support teams are at the other end of the line to answer any questions you may have about any of our cutting machines, or consumables.

oxy-Fuel

Cutting Machines

A tried and tested manufacturing process for mild steel, tailored for a wide range of industrial applications, ideal for plate between 3mm and 200mm. Opt for a cost effective method for component manufacture.

Oxy Fuel Machines

ultrasharp

Cutting Machines

Choose from our rapid selection of high-definition plasma cutting machines, for high quality components. Process machines for cutting mild steel from 1mm to 50mm thickness. Learn More

Ultrasharp Machines

Plasma

Cutting Machines

Laser quality cuts, at plasma cutting prices. Our in-house developed cutting technology, Ultrasharp, is sure to offer a cost effective alternative to laser cutting, without losing definition. Find Out More

Plasma Machines

waterjet

Cutting Machines

Our Optima range of Waterjet cutting machines bring flexibility to any manufacturing department, with a wide range of materials and thicknesses that can be cut with the waterjet process. Find Out More

Waterjet Machines
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