See

discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/226555877

Plasma arc cutting cost

Article in International Journal of Material Forming · August 2009

DOI: 10.1007/s12289-009-0588-4

CITATION READS

1 2,346

2 authors:

Sanda M. (Ilii) Bangu Margareta Coteata

Gh. Asachi Technical university of Iasi, Romania Gheorghe Asachi Technical University of Iasi
5 PUBLICATIONS 17 CITATIONS 83 PUBLICATIONS 159 CITATIONS

SEE PROFILE SEE PROFILE

Some of the authors of this publication are also working on these related projects:

dynoMat View project

All content following this page was uploaded by Sanda M. (Ilii) Bangu on 01 June 2014.

The user has requested enhancement of the downloaded file.

 PLASMA ARC CUTTING COST

S.M. Ilii1*, M. Coteaţă1**

1
Technical University of Iaşi – Romania, Faculty of Machine Manufacturing and Industrial
Management

ABSTRACT: In the machine manufacturing industries, cost estimation and costing are critical. In order to obtain
maximum of technical and economical efficiency, in these cases, very important is to estimate the production costs and
the production rates. Knowledge of investment and operating costs represents a base for investment in plasma arc
cutting machine. For different plasma arc cutting machines typical investment costs and operating costs depend from
the power of the plasma cutting machine and important system components. Knowledge of a plasma arc cutting
system’s investment and operating costs should form the basis for evaluating its profitability. The high investment and
operating costs, compared to conventional methods, must be justified according to economic criteria with corresponding
financial advantages. In this paper, a mathematical model for determining the cost of plasma arc cutting machining is
presented.

KEYWORDS: Plasma arc cutting, cost, estimation

1 INTRODUCTION be considered. Referring to workload & cost, in many

instances, a laser, for example, has to run for 20+ hours a
It is well known that the production plans made by the day to justify its existence and the amount of workload
production managers are based on serious calculations, has to be carefully considered. A plasma arc cutting
including those of operating cost and investment cost (if machine can often be an ideal alternative tool with
it is the case) besides those related with the quality that flexibility and low costs requiring a much lower
must be obtained. All those for one purpose: the utilization.
company profit.
The plasma arc cutting process provides many unique
2 PLASMA ARC CUTTING –
capabilities and advantages that can prove very effective
in the cost battle. OPERATING PRINCIPLE
The high investment and operating costs for plasma The machining technologies based on the thermal effect
cutting machines, compared to conventional cutting of plasma have an important place in the field of
machines, must be justified according to economic unconventional technologies. Nowadays, plasma arc
criteria with corresponding financial advantages. For cutting (PAC) is a widely used process to cut different
this, it is very important to estimate from the start, the materials and, combined with computer numerically
production costs and the production rates. controlled (CNC) machines, to cut alloy plate into
Only a detailed analysis of the technology solution desired shapes and prepare weld angles. The process is
together with an exact estimate of the part costs expected based on the thermal or chemical effects generated in the
during production provides an acceptable basis for an contact zones between plasma and the accessible
investment decision. surfaces of the workpiece.
If the finished product is presently being cut using, for Different variants of plasma arc cutting techniques are
example, oxy-fuel or laser, and no secondary operation is actually applied to practical purposes. Nowadays, the
needed to the part after being cut, it is unlikely plasma cutting process can be done either in atmosphere or
cutting will be an economical solution. Still, in many under water. The following variants are available: dual
cases, plasma cutting costs less than lasers. Although flow gas technique; water injection plasma cutting; air
lasers offer more accuracy and precision, PAC machines plasma (or compressed air technique); high tolerance
have a significant advantage over laser machines in plasma (so called precision plasma cutting).
terms of acquisition cost, maintenance and productivity. Plasma cutting refers to metal cutting by melting with a
Before buying a PAC machine, purchase & running constricted arc, then blowing the molten metal out of the
costs, along with long term maintenance must carefully kerf with a hight-velocity jet of ionized gas.
____________________
* Technical University of Iasi, Romania, Faculty of Machine Manufacturing and Industrial Management, B-dul D. Mangeron, No.
59A, Tel.: Mobile: +40 747 703 677 or +40 232 278 680, Fax. +40 232 217 290, E-mail: sandasist@yahoo.com;
** Technical University of Iasi, Romania, Faculty of Machine Manufacturing and Industrial Management, B-dul. D. Mangeron, No.
59A, Tel.: +40 232 278 680, Fax. +40 232 217 290, E-mail: marg_co@yahoo.com.
Metal plasma cutting devices are widely used in
industry, and recent developments of torch design
together with the use of oxygen as plasma producing gas
allow improvement in cutting quality [1, 2]. Because of
its oxidizing properties, oxygen leads to more regular
surfaces inside the kerf with a better evacuation of the
molten metal and less dross formation beneath the
workpiece with increased cutting speeds [3].
Plasma arc cutting is a very complex process that is used
in order to cut steel and other metals (or sometimes other
materials) using a plasma torch. In this process, an inert
gas is blown at high speed out of a nozzle, see Figure 1.
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. Due to the height
concentration of the energy in a limited space, the
material of the workpiece is wormed till the melting of a
layer; afterwards, the melted material is removed from
the cut by the plasma jet [2, 10].
Figure 1: Plasma Arc Cutting process [4, 5]
How it works. The cutting procedure begins with arc
ignition, which is a process consisting of several steps. It
starts with igniting a pilot arc, an arc discharge between
the electrode (cathode) and nozzle, see Figure 2, a.
Ignition of this pilot arc can be done in two different
ways: one is with a short HF pulse applied to the
electrode-nozzle gap, another is retract starting. The
most common form of retract starting uses the pressure
of the air supplied to the torch to drive back a piston to
which the electrode is ultimately connected. The
electrode and nozzle start out in contact with an electric
current running through them. When the electrode
retracts a pilot arc is created [6, 7, 8].
Once the pilot arc is created, the gas flow blows the pilot
arc out of the nozzle thus creating an arc loop protruding
out of the nozzle. If the work-piece is in position
(typically within 5–15mm from the end of the nozzle),
the arc will attach to the work-piece, the power supply
will sense arc transfer and the nozzle will be removed
from the circuit. The workpiece becomes the anode, and
the main current establishes in the electrode-work gap
[6, 7, 8].
a) Pilot arc ignition b) Arc transfer
Figure 2: Plasma arc cutting phases [6, 7, 8]
There are two methods to begin the cutting process:
piercing the plate or starting from the edge of the plate.
3 PARAMETERS THAT INFLUENCE
PLASMA ARC CUTTING AND COST
Plasma arc cutting process depends on a large number of
process parameters such as: plasma gas flow-rate, orifice
diameter, standoff distance, cutting speed etc.
In Figure 3 it is presented a schematic representation of
parameters that influence the plasma arc cutting process
and cost.
The power of the plasma generator is the determining
factor in the operating costs for the plasma cutting.
Cutting speed is the key parameter to reduce the
operating cost. The key is to cut as fast as possible,
fastest cut speed – lowest cost per meter. The speed at
witch the plasma arc can cut through material will vary
based on a variety of parameters, such as: plasma arc
current intensity and plasma arc voltage, workpiece
material type and thickness, the quality of the edge finish
and tolerance.
Quality Productivity
- Plasma arc current intensity;
- Plasma arc voltage;
- The type of the plasma gas used;
- The plasma gas flow-rate;
- The nozzle orifice diameter;
- Thickness of the workpiece;
- The cutting speed;
- Standoff distance;
- Plasma torch position to the plate.
Profit
Figure 3: Schematic representation of parameters that
influence the P.A.C. process and cost
The plasma gas used in the cutting process influence
directly the quality of the obtained surfaces, the cutting
speed, and the wear of the nozzle, the appearance of
toxic oxides, the use of one type of the electrode or
another and not the last, the operation cost. The
plasmogen gas or primary gas must ensure protection to
the incandescent electrode against the oxidation process
and also, must be neutral toward the material workpiece.
The mono-atomic inert gases, witch are today the most
used to produce thermal plasma (Argon, Helium, Azoth,
air etc.), accomplish these conditions.
Maintenance is one of the parameters that also influence
the cutting cost. Like any other machine, plasma cutting
equipment has parts that wear and must be replaced
occasionally.
Most of the performance of a plasma system happens in
the torch. High pressure gas flows are controlled by the
features and positioning of the consumables to shape the
40.000° F plasma arc.
Plasma cutting torches have a variety of wear items that
require replacement, commonly called consumables. A
smaller number of consumables mean less to replace and
more cost savings. Also, short consumable life leads to
reduced productivity and higher consumable costs.
Consumption of wear parts vary by machine and
application.
Figure 4: Costs of metal cutting [9]
According to [9], labour and overhead are by far the
largest cost component of cutting metal, as shown in the
Figure 4. Consumables only account for about 10% of
the cost associated with labour and overhead.
4 MATHEMATICAL MODEL FOR
DETERMINING THE COST OF P.A.C.
MACHINING
Assumptions: Three categories make the cost of plasma
arc cutting: depreciation cost of initial investment,
operating cost and labour cost. Thus, the plasma cutting
cost per hour can be calculated through the following
equation:
CTotal = C d + Cop + C L [Eur/h] (1)
where CTotal is the plasma cutting cost per hour, (Eur/h);
Cd - Depreciation cost of initial investment, (Eur/h);
Cop – Operating cost, (Eur/h); Cl – Labour cost, (Eur/h).
Depreciation cost is associated with the equipment
purchase. It is the initial price of the equipment
amortized over a specific amount of time. For different
plasma arc cutting machines typical investment costs
depend from the power of the plasma cutting machine
and important system components, as well as the size of
the working area, the accuracy of the positioning
systems. While the investment cost of a plasma cutting
machines may seams high, improved productivity and
product quality, combined with low tooling and
maintenance costs, often make a system economical,
especially for companies that produce a wide range of
parts. The depreciation cost of initial investment can be
calculated through the following equation:
I
Cd = [Eur/h] (2)
Pa ⋅ Tu
where Cd is the depreciation cost of initial investment, in
(Eur/h); I – capital investment cost of plasma cutting
machine, (Eur); Pa – the depreciation period (year);
Tu – the machine utilization (h/year).
The operating cost is associated with operating the
process, including electric energy consumption, plasma
gas consumption, wear parts consumption, maintenance
and repair. These costs occur only when the machine is
operating. The operating cost depends from specific
applications. Operating cost includes cost of power, of
plasma gas and consumables such as electrodes and
nozzles etc. It does not include labour, lease of
depreciation, facilities, or other overhead costs.
The calculation for operating cost is specific to the
plasma arc process. Operating cost comprises costs of
electric energy consumption, plasma gas cutting
consumption, wearing parts consumption and
maintenance of the machine:
Cop = Ce + C gt + C gp + C c + C m [Eur/h] (3)
where Cop is the operating cost, (Eur/h); Ce – cost of
electric energy, (Eur/h); Cgt – plasma gas cost, (Eur/h);
Cgp – secondary plasma gas cost, (Eur/h); Cc – cost of
wear parts, (Eur/h); Cm – maintenance cost, (Eur/h).
The cost of electric energy can be calculated through
equation (4):
C e = cue ⋅ E [Eur/h] (4)
where cue is the unit cost of electric energy, (Eur/kWh);
E – electric power consumption, (kW).
The plasma gas cost can be calculated through
equation (5):
C gt = c gp ⋅ Gt [Eur/h] (5)
where cgt is the unit cost of plasma gas, (Eur/m3);
Gt – plasma gas consumption, (m3/h).
The secondary plasma gas cost can be calculated through
equation (6):
C gp = c gp ⋅ G p [Eur/h] (6)
 where cgp is the unit cost of secondary plasma gas, where CTotal is the plasma arc cutting cost, (Eur/h);
(Eur/m3); Gp – secondary plasma gas consumption, v – the cutting speed, (mm/min).
(m3/h).
The cost of wear parts can be calculated with: 5 CONCLUSIONS
The plasma arc cutting process provides many unique
c c capabilities and advantages that can prove very effective
C c = U el + U d = el + d [Eur/h] (7) in the cost battle.
Del Dd
Plasma provides an optimal mix of quality, productivity
where Uel is the electrode wear, (Eur/h); Ud - plasma arc and operating cost for mild steel, stainless and
orifice wear cost per hour, (Eur/h); cel – the unit cost of aluminium across a wide range of thicknesses at a
an electrode, (Eur/piece); Del – the lifetime of an competitive capital equipment price.
electrode, (h); cd – the unit cost of a nozzle, (Eur/piece); Long consumable life, good productivity and excellent
Dd – the lifetime of a nozzle, (h). cut quality drive the cost per part lower than other
technologies.
The maintenance cost can be calculated with:
ACKNOWLEDGEMENT
M
Cm = [Eur/h] (8)
Tu The preparation of this work would not have been
possible without the support, hard work and efforts of
where M is the maintenance costs per year, (Eur/year); the staff from Technical University of Iaşi, Romania,
Tu – machine utilization, (h/year). Faculty of Machine Manufacturing and Industrial
Management.
Plasma arc cutting cost per hour, according to equations
(1) to (8) can be calculated through equation (9):
REFERENCES
I [1] Gage, R.M. (1959). The principles of the Modern
CTotal = + cue ⋅ E + c gt ⋅ Gt + c gp ⋅ G p +
Pa ⋅ Tu Arc Torch, Welding Journal, 38 959–62.
(9) [2] Gutt, Gh., Sonia (1992), Tehnologii
cel c M
+ + d + + C L [ Eur / h ] Neconvenţionale, Editura Terhnica, Bucuresti.
Del Dd Tu [3] Teulet, Ph., Girard, L.(2006) Razafinimanana, M. Et
alt. Experimental study of an oxygen plasma cutting
The labour cost is associated with running the machine, torch: II. Arc–material interaction, energy transfer
including the time to handle raw-material, finished parts and anode attachment, Institute of Physics
and remnants and attending the machinery while it’s Publishing Journal of Physics D: Applied Physics.
running. To place a value on these costs, it must know [4] Bâlc, N. (2001). Tehnologii neconventionale,
the hourly cost of an operator, the amount of time it Editura Dacia, Cluj-Napoca.
takes to run a part on machine, the percentage of time [5] TWI World Centre for Materials Joining
allotted for machine setup and the percentage of time Technology, Cutting processes – plasma arc cutiing
while an operator actually attends the machine. – process and equipment considerations, Available
Manufacturing cost can be calculated through: at:http://www.twi.co.uk/j32k/protected/band_3/jk51.
html, Accessed: 2006-03-23.
C m = C ⋅ t m [Eur/h] (10) [6] Nemchinsky, V.A. (1998). Plasma flow in a nozzle
during plasma arc cutting, In Journal of. Physics, D:
where C is the manufacturing cost, (Eur) and Appl. Phys. 31 3102–7.
tm – manufacturing time, (h). [7] Dobre, M., Nistor, R. (1996). Fizica plasmei. Note
de curs pentru uzul studenţilor, Editura Universităţii
Manufacturing time can be calculated through Politehnica, Catedra de Fizică, Bucureşti.
equation (11): [8] Marinescu, N.I., Nanu, D., Lăcătuş, E. et al. (2000).
Procese de prelucrare cu fascicule şi jeturi,
L Institutul Naţional de Optoelectronică, Bucureşti.
tm = [min] (11)
v [9] Hypertherm Plasma Consumables Overview,
where L is the length of the cut, (Eur/m); v – the cutting Avaible at: http://www.messer-
speed, (mm/min). cw.co.uk/Products/Consumables/Hypertherm-
Overview.htm, Accessed: 2007-02-20.
Plasma arc cutting cost per meter is established as: [10] Sommer, C. Non-Traditional Machining Handbook,
Houston: Advance Publishing. Inc, ISBN 1-57537-
C Total 325-4.
C* = [Eur/m] (12)
v

View publication stats