Evaluation of the Effectiveness of Plasma Torches Design for Metal Cutting by Qualimetric Method

2019 ◽  
Vol 946 ◽  
pp. 877-882
Author(s):  
I.Y. Matushkina ◽  
S.V. Anakhov ◽  
Yu.A. Pyckin
Keyword(s):  
Metal Cutting ◽  
Quality And Safety ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
Work Efficiency ◽  
Integral Evaluation ◽  
Plasma Arc Cutting ◽  
Plasma Torches ◽  
Safety Parameters ◽  
Experimental Substantiation

For experimental substantiation of plasmatrons work efficiency the technological regulations of quality and safety parameters test for plasma-arc cutting of metals technology are taken. For the integral evaluation of the obtained results it is proposed to use the methods of qualimetric analysis adapted to the technology of plasma cutting. The obtained integral parameters indicate the effectiveness of the new plasmatrons, designed by the authors in comparison with previously produced analogues, as well as with modern domestic and foreign samples.

scholarly journals Comparison of laser beam, oxygen and plasma arc cutting methods in terms of their advantages and disadvantages in cutting structural steels

2021 ◽  
Vol 2130 (1) ◽  
pp. 012022
Author(s):  
G Írsel ◽  
B N Güzey
Keyword(s):  
Laser Beam ◽  
Metal Cutting ◽  
Cost Effective ◽  
Cutting Process ◽  
Oxygen Mixture ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
Setup Cost ◽  
Plasma Arc Cutting ◽  
Advantages And Disadvantages

Abstract The laser beam, plasma arc, and oxygen cutting methods are widely used in metal cutting processes. These methods are quite different from each other in terms of initial setup cost and cutting success. A powered laser beam is used in laser beam cutting, plasma is used in plasma arc cutting, flammable gas - oxygen mixture is used in the oxygen cutting method. In this study, the cutting success of these methods was investigated on tensile specimens. Microstructure, hardness (HV 0.1), surface roughness, and strengths were investigated after the cutting process. The tensile test implemented with tensile samples cut from the same material by these three methods, it was observed that the strength values of the samples changed by about 8% in tensile strength depending on the cutting process. The hardness of the cut surfaces in plasma arc cutting increased from 150 HV to 230 HV for S235JR material. For this reason, it is difficult to perform machining operations after plasma cutting. The hardness value reached after laser beam cutting is 185 HV. Plasma arc cutting is more cost-effective than laser beam cutting. 1-3° vertical inclination (conicity) occurs on the cut surface in plasma arc cutting, while this inclination almost does not occur in laser cutting. In plasma cutting benches, cutting is done with oxygen, and in cutting with oxygen, the taper is seen in a small amount.

scholarly journals Prediction and Analysis of Multi-Response Characteristics on Plasma Arc Cutting of Monel 400™ Alloy Using Mamdani-Fuzzy Logic System and Sensitivity Analysis

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3558
Author(s):  
Rajamani Devaraj ◽  
Emad Abouel Nasr ◽  
Balasubramanian Esakki ◽  
Ananthakumar Kasi ◽  
Hussein Mohamed
Keyword(s):  
Sensitivity Analysis ◽  
Fuzzy Logic ◽  
Metal Cutting ◽  
Removal Rate ◽  
Cutting Speed ◽  
Average Error ◽  
Plasma Arc ◽  
Plasma Arc Cutting ◽  
Response Characteristics ◽  
Monel 400

Nickel-based alloys, especially Monel 400™, is gaining its significance in diverse applications owing to its superior mechanical properties and high corrosion resistance. Machining of these materials is extremely difficult through the traditional manufacturing process because of their affinity to rapid work hardening and deprived thermal conductivity. Owing to these difficulties a well-established disruptive metal cutting process namely plasma arc cutting (PAC) can be widely used to cut the sheet metals with intricate profiles. The present work focuses on an intelligent modeling of the PAC process and investigation on the multi-quality characteristics of PAC parameters using the fuzzy logic approach. The Box-Behnken response surface methodology is incorporated to design and conduct the experiments, and to establish the relationship between PAC parameters such as cutting speed, gas pressure, arc current, and stand-off distance and responses which include the material removal rate (MRR), kerf taper (KT), and heat affected zone (HAZ). The quadratic regression models are developed and their performances are assessed using the analysis of variance (ANOVA). Fuzzy set theory-based models are formulated to predict various responses using the Mamdani approach. Fuzzy logic and regression results are compared with the experimental data. A comparative evaluation predicted an average error of 0.04% for MRR, 0.48% for KT, and 0.46% for HAZ, respectively. The effect of variations in PAC process parameters on selected responses are estimated through performing the sensitivity analysis.

scholarly journals The influence of plasma gas on changes in chemical composition and structures during the cutting process

2021 ◽  
Vol 13 (3) ◽  
pp. 151-157
Author(s):  
Agnieszka Rzeźnikiewicz ◽  
◽  
Jacek Górka ◽  
Keyword(s):  
Liquid Metal ◽  
Chemical Elements ◽  
Hydrogen Plasma ◽  
Cutting Process ◽  
Material Structure ◽  
Chemical Compositions ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
Air Plasma ◽  
Plasma Arc Cutting

Cutting is usually one of initial and basic operations of the manufacturing process of welded structures and realization constructions elements. Thermal cutting, in particular plasma arc cutting is often used to prepare elements. The plasma arc cutting process involves melting and ejecting the liquid metal from the cutting gap with a highly concentrated plasma electric arc which is generated between the non-consuable electrode and the workpiece. The paper presents the results of research on the influence of plasma gas on structural changes and chemical compositions changes resulting unalloyed steel cutting by air plasma arc. It was shown that in the air plasma arc cutting process the amorphous layer with a very high nitrogen content (about 1.6%) and a hardness of 750 HV 0.2 was used. This high nitriding effect is due to the diffusion of nitrogen from the plasma gas. As a result of the interaction of air plasma arc gases on the liquid metal, the cutting surface is carburized (about 0.5%). The alloy components are also burnt according to the theory of selective oxidation of chemical elements. The material structure after the air plasma cutting process shows the structures between the structure formed after oxygen cutting processs and nitrogen plasma cutting process. The process of argon-hydrogen plasma cutting has the least influence on the cut material.

Development and research of new technologies for precision plasma cutting of metals

2021 ◽  
Vol 77 (7) ◽  
pp. 829-834
Author(s):  
S. V. Anakhov ◽  
Yu. A. Pykin ◽  
A. V. Matushkin ◽  
B. N. Guzanov
Keyword(s):  
Plasma Torch ◽  
Metal Cutting ◽  
New Technologies ◽  
Arc Discharge ◽  
Experimental Studies ◽  
Carbon Steels ◽  
Plasma Cutting ◽  
Medium Thickness ◽  
Plasma Torches ◽  
Gas Dynamic

Plasma torches of Russian origin concede to import metal-cutting plasma facilities by several parameters, in particular energy efficiency, quality of cut, degree of automation. To increase efficiency and safety of domestic electro-plasma technologies itь is necessary to perfect methods of analysis of known design solutions to provide new developments. The results of the plasma torch­es design widely used in metallurgical and machine-building technologies for air-plasma cutting of metals presented. It was noted that productivity, cutting quality and reliability of plasma equipment should be chosen as the main criteria of efficiency for plasma cutting technology. It was shown that special attention should be paid to improving the gas-vortex stabilizing method for the plasma forming gas, which ensures the efficiency of both the plasma torch and the plasma cutting process as a whole. Results of studies of a complex system for arranging the flow of plasma-forming gas through the channels of the gas-air path in the plasma torch and the subsequent creation of new systems for stabilizing the arc discharge of metal cutting DC plasma torches with high technological capabilities presented. The study was carried out by the methods of numerical simulation of gas-dynamic and thermo-physical pro­cesses for various designs of plasma torches. Optimized designs of plasma torches with various variants of gas-vortex stabilization systems were elaborated. A series of elaborated torches, which includes a single-stream plasma torches ПМВР-5 for precision cutting of medium thickness metals, as well as two-stream plasma torches ПМВР-9 for cutting metals of small and medium thicknesses presented. The last plasma torches use the technology of narrow-jet or compressed plasma and have no domestic analogues. A meth­odology of metal-cutting plasma torches designing by gas-dynamic, thermo-physical and acoustic criteria was elaborated. The results of experimental studies  showed that the use of new ПМВР-5 plasma torches allows to obtain precision cuts corresponding to the 1st and 2nd quality classes according to GOST 14792-80 on steels of the 09Г2С type of medium thickness. It was also shown that the use of new plasma torches makes it possible to perform precision finishing plasma cutting on low-carbon steels of medium thickness (without additional mechanical processing of the cutting edge) in the production technologies of welded joints.

PREDICTIVE MODELING OF SURFACE ROUGHNESS, MATERIAL REMOVAL RATE AND KERF USING MULTIPLE REGRESSION ANALYIS IN PLASMA ARC CUTTING PROCESS OF HARDOX AND ABREX STEEL

2020 ◽  
Vol 27 (09) ◽  
pp. 1950206
Author(s):  
DEEPAK KUMAR NAIK ◽  
KALIPADA MAITY
Keyword(s):  
Surface Roughness ◽  
Multiple Regression ◽  
Material Removal Rate ◽  
Material Removal ◽  
Metal Cutting ◽  
Removal Rate ◽  
Cutting Speed ◽  
High Strength ◽  
Plasma Arc ◽  
Plasma Arc Cutting

Plasma arc cutting (PAC) process is widely used in metal cutting industries and modern fabrication units. Precise cutting of high strength material is still a challenging task to the industries. PAC process uses thermal energy to melt the material through highly energized plasma gas. Mostly, “hard-to-cut” type materials is used to cut through this process to meet the demands. The present work proposes an experimental investigation of PAC process of hardox 400 and abrex 400. Both the materials are high strength and high abrasion resistance in nature. Experiments were conducted based on Taguchi’s L[Formula: see text] orthogonal array design. The cutting parameters analyzed were arc current, cutting speed, stand-off distance and supply gas pressure whereas material removal rate, kerf and surface roughness were selected as responses. Also, a prediction model was developed to estimate the responses using multiple regression analysis. A comparison between experimental and predicted result shows the accuracy of the model. Analysis of variance (ANOVA) was used to verify the effect of each parameter on the surface quality to be assessed.

scholarly journals Influence of plasma torch design on cutting quality during precision air-plasma cutting of metal

2020 ◽  
Vol 63 (2) ◽  
pp. 155-162
Author(s):  
S. V. Anakhov ◽  
B. N. Guzanov ◽  
A. V. Matushkin ◽  
N. B. Pugacheva ◽  
Ya. A. Pykin
Keyword(s):  
Plasma Torch ◽  
Dynamic Stabilization ◽  
Quality Analysis ◽  
Metallographic Analysis ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
09G2s Steel ◽  
Plasma Torches ◽  
Gas Dynamic

Optical interferometry and metallographic analysis were used to study structure of cutting seams obtained after 09G2S steel cutting by PMVR-5 plasma torch. These plasma torches have a number of design features in the system of gas-dynamic stabilization of plasma arc. It is shown that application of new plasma torch allows obtaining higher quality of cutting 09G2S steel of medium thickness with high productivity and lower energy costs. Metallographic analysis has shown that qualitative composition of the cut surface structure is almost the same, so priority criteria for comparative quality analysis are parameters of surface microgeometry. Evaluation of this parameter shows high quality of cutting almost along the entire length of a cut, since the influence of technological features of plasma arc cut into the metal affects at a distance of less than 0.3 mm from the edge of the sheet. The use of additional methods of gas-dynamic stabilization in PMVR -5.2 plasma torch (feed symmetry with a double swirl system of plasma-forming gas) allows to achieve additional advantages in terms of surface quality compared to PMVR -5.1. A number of features that affects quality of cut when cutting metals of different thicknesses for welding, is noted depending on the angle of inclination of plasma torch during cutting. Estimates of the surface layer hardness indicate minimal deviations from the requirements of GAZPROM Standard 2-2.4-083 (instructions on welding technologies in the construction and repair of field and main gas pipelines), which allows further use of cutting seams obtained by studied plasma torches for welding without removing zones of thermal influence. Thus, application of new plasma torches makes possible precision finishing plasma cutting of metals, including production of welded joints.

Experimental study of mild steel cutting process by using the plasma arc method

2021 ◽  
Vol 108 (2) ◽  
pp. 75-85
Author(s):  
H.M. Magid
Keyword(s):  
Industrial Process ◽  
Scanning Speed ◽  
Cutting Parameters ◽  
Operating Conditions ◽  
Kerf Width ◽  
Cutting Process ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
Cutting Equipment

Purpose: In this study, plasma arc cutting (PAC) is an industrial process widely used for cutting various away types of metals in several operating conditions. Design/methodology/approach: It is carried out a systematic or an authoritative inquiry to discover and examine the fact, the plasma cutting process is to establish the accuracy and the quality of the cut in this current paper assessed a good away to better the cutting process. Findings: It found that the effect of parameters on the cutting quality than on the results performed to accomplish by statistical analysis. Research limitations/implications: The objective of the present work paper is to achieve cutting parameters, thus the quality of the cutting process depends upon the plasma gas pressure, scanning speed, cutting power, and cutting height. Practical implications: The product of the plasma cutting process experimentally has been the quality of the cutting equipment that was installed to monitor kerf width quality by exam the edge roughness, kerf width, and the size of the heat-affected zone (HAZ). Originality/value: The results reveal that were technically possessed of including all the relevant characteristics, then a quality control for the cutting and describe the consequence of the process parameters.

Increased Duty Cycle for Plasma Arc Cutting Machines Through a Separated Automatic Plate Marking Station

1989 ◽  
Vol 5 (04) ◽  
pp. 207-227
Author(s):  
J. M. Sizemore ◽  
D. P. Rome
Keyword(s):  
Duty Cycle ◽  
Fabrication Process ◽  
Plasma Arc ◽  
Technical Feasibility ◽  
Plasma Arc Cutting ◽  
Cutting Machine ◽  
Percent Increase

Plate marking as currently practiced limits plasma arc cutting machine duty cycle. This, in turn, constrains plate fabrication process lane throughput. A separate automatic plate marking station which will significantly increase plasma arc cutting capacities is defined. A 60 to 100 percent increase in plate fabrication process lane throughput is anticipated while simultaneously reducing unit direct labor. The design is supported by technical feasibility demonstrations.

Hybrid Induction Plasma Cutting Process - A New Technology for High Speed Metal Cutting

2014 ◽  
Author(s):  
Jerald E. Jones ◽  
Valerie L. Rhoades ◽  
Mark D. Mann ◽  
Todd Holverson
Keyword(s):  
Induction Heating ◽  
Plasma Torch ◽  
High Speed ◽  
Metal Cutting ◽  
New Technology ◽  
Cutting Process ◽  
Plasma Cutting ◽  
Air Plasma ◽  
Aircraft Carrier ◽  
Initial Development

A new cutting process, a hybrid system, uses induction heating to heat the metal ahead of the plasma cutting torch. The process has demonstrated the ability to plasma cut steel parts at speeds of up to 4X the speed of the plasma torch without the induction heating. Although the total heat input per unit time is greater, because of the increase in speed, the heat which is conducted into the cut pieces is less. This causes less potential metallurgical damage, less potential distortion, and reduced coating damage and reduced emissions during cutting, in comparison to the plasma cutting process without the induction heating. The initial development was primarily for use in cutting nuclear submarine and aircraft carrier hulls, for scrapping after decommissioning. The process has been demonstrated cutting steel plates and can be used in ship production as well. The primary motivation of the SBIR project was to reduce the heating of the cut pieces, in order to reduce the particulate matter (PM) emissions which occur when coated ship hull material is cut. An induction coil is positioned in front of the plasma cutting torch, to bring the material to an elevated temperature of at least 1600° F, before the plasma is applied to the metal surface. Induction heating testing has shown that the 35 kW induction system can maintain the 1600° F surface temperature at travel speeds of above 220 inches per minute on steel as thick as 3 inches. Once the steel is at that temperature an air plasma torch can cut the metal much faster than cutting cold steel.

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