- This article is about the common manufacturing process. Manufacturing (from Latin manu factura, "making by hand" is the use of tools and labor to make things for use or sale For various fictional weapons, see plasma rifle and directed-energy weapon. Plasma rifles are theoretical weapons often used in Science fiction. A directed-energy weapon ( DEW) is a type of weapon that emits Energy in an aimed direction without the means of a Projectile.
Plasma cutting is a process that is used to cut steel and other metals (or sometimes other materials) using a plasma torch. Steel is an Alloy consisting mostly of Iron, with a Carbon content between 0 The M acro E xpansion T emplate A ttribute L anguage complements TAL, providing macros which allow the reuse of code across A plasma torch (or plasma arc or plasma gun) is a device that generates a directed flow of plasma from its nozzle In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. In Physics and Chemistry, plasma is an Ionized Gas, in which a certain proportion of Electrons are free rather than being bound The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Plasma can also be used for plasma arc welding and other applications. Plasma arc welding (PAW is an arc Welding process similar to Gas tungsten arc welding (GTAW
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Process
The HF Contact type typically found in budget machines uses a high frequency high voltage spark to ionise the air through the torch head and initiate an arc. The arc can only be formed if the torch is in contact with the job material. HF Contact type machines are not suitable for applications involving CNC cutting.
The Pilot Arc type uses a two cycle approach to producing plasma. First, a high-voltage, low current circuit is used to initialize a very small high intensity spark within the torch body, thereby generating a small pocket of plasma gas. The volt (symbol V) is the SI derived unit of electric Potential difference or Electromotive force. An electrical network is an interconnection of Electrical elements such as Resistors Inductors Capacitors Transmission lines Voltage This is referred to as the pilot arc. The pilot arc has a return electrical path built into the torch head. The pilot arc will maintain until it is brought into proximity of the workpiece where it ignites the main plasma cutting arc. Plasma arcs are extremely hot and are in the range of 15,000 degrees Celsius.
Plasma is an effective means of cutting thin and thick materials alike. Hand held torches can usually cut up to 2 in (48 mm) thick steel plate, and stronger computer-controlled torches can pierce and cut steel up to 12 inches (300 mm) thick. Steel is an Alloy consisting mostly of Iron, with a Carbon content between 0 Formerly, plasma cutters could only work on conductive materials, however new technologies allow the plasma ignition arc to be enclosed within the nozzle thus allowing the cutter to be used for non-conductive workpieces.
Since plasma cutters produce a very hot and very localized 'cone' to cut with, they are extremely useful for cutting sheet metal in curved or angled shapes.
Starting methods
Plasma cutters use a number of methods to start the pilot arc, depending on the environment the unit is to be used in and its age. Older cutters use a high voltage, high frequency circuit to start the arc. This method has a number of disadvantages, including risk of electrocution, difficulty of repair, sparkgap maintenance, and the large amount of radio frequency emissions. Radio frequency ( RF) is a Frequency or rate of Oscillation within the range of about 3 Hz to 300 GHz Plasma cutters working near sensitive electronics, such as CNC hardware or computers, use the contact start method. The abbreviation CNC stands for computer numerical control, and refers specifically to a computer "controller" that reads G-code The nozzle and electrode are in contact. The nozzle is the cathode, and the electrode is the anode. A cathode is an Electrode through which (positive Electric current flows out of a polarized electrical device An anode is an Electrode through which Electric current flows into a polarized electrical device When the plasma gas begins to flow, the nozzle is blown forward. A third, less common method is capacitive discharge into the primary circuit via a Silicon Controlled Rectifier. A silicon-controlled rectifier (or semiconductor-controlled rectifier) is a four-layer solid state device that controls current.
Inverter plasma cutters
Analog plasma cutters, typically requiring more than 2 kilowatts, use a heavy mains frequency transformer. Inverter plasma cutters rectify the mains voltage into DC, which is fed into either an IGBT or a MOSFET. The insulated-gate bipolar transistor or IGBT is a three-terminal Power semiconductor device, noted for high efficiency and fast switching The metal–oxide–semiconductor field-effect transistor ( MOSFET, MOS-FET, or MOS FET) is a device used to amplify or switch electronic signals With paralleled MOSFET transistors if one of the transistors activates prematurely it can lead to a cascading failure of one quarter of the inverter. Later invention, IGBT transistors when not used in this paralleled fasion will not blow out that easily. IGBTs can be generally found in high current machines where it is not possible to parallel sufficient MOSFET transistors. Switching frequency used ranges from about 10kHz to about 200kHz, depending on the ability of the switching transistors and rectifiers; higher switching frequency greatly reduces the magnetic flux in the step down transformer, and therefore the size of the transformer is reduced accordingly. The switch mode topology is referred to as a dual transistor off-line forward converter. A switched-mode power supply, switching-mode power supply or SMPS, is an electronic Power supply unit (PSU that incorporates a switching regulator Although lighter and more powerful, some inverter plasma cutters, especially those without power factor correction, cannot be run from a generator (that means manufacturer of the inverter unit forbids to do so; it is only valid for small, light portable generators). However newer models have internal circuitry that allow units without power factor correction to run on light power generators.
Plasma cutting is a very efficent and easy way to cut many types of metal.
Plasma gouging
Plasma gouging is a related process, typically performed on the same equipment as plasma cutting. Instead of cutting the material, plasma gouging uses a different torch configuration (torch nozzles and gas diffusers are usually different), and a longer torch-to-workpiece distance, to blow away metal. Plasma gouging can be used in a variety of applications, including removing a weld for rework. The additional sparks generated by the process requires the operator to wear a leather shield protecting their hand and forearm. Torch leads also can be protected by a leather sheath.
CNC cutting methods
Plasma cutters have also been used in CNC (computer numerically controlled) machinery. The abbreviation CNC stands for computer numerical control, and refers specifically to a computer "controller" that reads G-code Manufacturers build CNC cutting tables, some with the cutter built in to the table. The idea behind CNC tables is to allow a computer to control the torch head making clean sharp cuts. Modern CNC plasma equipment is capable of multi-axis cutting of thick material, allowing opportunities for complex welding seams on CNC welding equipment that is not possible otherwise. For thinner material cutting, plasma cutting is being progressively replaced by laser cutting, due mainly to the laser cutter's superior hole-cutting abilities. Laser cutting is a technology that uses a Laser to cut materials and is typically used for industrial manufacturing applications
A specialized use of CNC Plasma Cutters has been in the HVAC industry. HVAC (pronounced either "H-V-A-C" or occasionally " H-vak " is an Initialism or Acronym that stands for " Heating Software will process information on ductwork and create flat patterns to be cut on the cutting table by the plasma torch. Ducts are used in heating ventilation and air conditioning ( HVAC) to deliver and remove air This technology has enormously increased productivity within the industry since its introduction in the early 1980s.
New technology
In the past decade plasma torch manufacturers have engineered new models with a smaller nozzle and a thinner plasma arc. This allows near laser quality on plasma cut edges. Several manufacturers have combined precision CNC control with these torches to allow fabricators to produce parts that require little or no finishing.
Costs
Plasma torches were once quite expensive, usually at least a thousand U.S. dollars. The United States dollar ( sign: $; code: USD) is the unit of Currency of the United States; it has also been For this reason they were usually only found in professional welding shops and very well-stocked private garages and shops. However, modern plasma torches are becoming cheaper, and now are within the price range of many hobbyists. Older units may be very heavy, but still portable, while some newer ones with inverter technology weigh only a few pounds yet equal or exceed the capacities of older ones. An inverter is an electrical or electro-mechanical device that converts Direct current (DC to Alternating current (AC the resulting AC can be at any required voltage
See also
External links
Plasma arc welding (PAW is an arc Welding process similar to Gas tungsten arc welding (GTAW A water jet cutter is a tool capable of slicing into Metal or other materials using a jet of Water at high velocity and pressure or a mixture of water and anDapyx Software network: MP3 Explorer | Ebook Manager | Zenithic