PLASMA CUTTING MACHINES
What is plasma cutting?
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
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
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
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.
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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.
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.
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oxy-Fuel
Cutting Machines
For the best quality and the most precise cuts, OXY-FUEL profile cutting machines are certainly an excellent option to explore. At Kerf, your first choice for CNC cutting machine manufacturer, we can provide a wide range of different OXY-FUEL cutting machine options. Oxy-fuel cutting is a method that has been around for more than a century, dating back to 1907. However, it is still widely used today and is a critical component and technology in many sectors.
To cut metals, oxy-fuel cutting uses a mix of fuel gases and oxygen. A number of fuels may be used, with acetylene being the most popular. Speak to Kerf about our profile cutting machines to find out more.
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.
Plasma
Cutting Machines
Plasma cutters pass an electrical arc through gas (often compressed air), which converts into a plasma arc that is used to cut through the metal. The interaction of gases, high speeds, and a concentrated region of pressure results in electrically conductive ionised gas, commonly known as plasma. This technique is used on metals that cannot be cut with flame cutting equipment.
Compared to laser profile cutting which utilises fiber lasers and in which the laser beam does the heavy duty work for you, the plasma CNC machine is perhaps less accurate, but it is faster and can cut through heavier materials. That said, the fiber laser cutting machine certainly has as much a place in construction as the plasma cutting machine does, so don’t hesitate to ask us if you need one or both – or any other – cutting machine. We can help you no matter what cutting machine requirements you might have.
Waterjet
Cutting Machines
Not only can this cutting method get through almost any material you ask it to, but it leaves you with little to no waste, and it is an extremely accurate profile cutting method. When it comes to choosing a cutting system that will offer you everything you need, waterjet cutting ticks all the boxes.
Waterjet cutting employs an abrasive grit carried by an ultra-high pressure stream of water. The abrasive grit cuts using a mechanical sawing motion and results in a smooth, precision cut surface created at high speed.
Waterjet is the most adaptable method since it can cut nearly any material; even carbon steel is no match for it. Materials that are extremely fragile, such as tempered glass and certain ceramics, are among the limitations, however. Waterjet cutting is an extremely accurate procedure. It features a tiny kerf width, which allows for the cutting of delicate curves and the production of high tolerance components.
