POWER OF MINIATURE PARTICLE

***
PLASMA ARC CUTTING
Presented By:-

Deepak Gambhir
Under the Guidance of

Mr. Bankim Desai (Shop In-Charge)

Mr. Ashish Gandhi (Production
Supervisor)
PLASMA ARC CUTTING
Presented By:-

Deepak Gambhir
Under the Guidance of

Mr. Bankim Desai (Shop In-Charge)

Mr. Ashish Gandhi (Production
Supervisor)
 PLASMA

Ionized gases are known as PLASMA

It is a mixture of free electrons, positively

charged ions and highly excited neutral
atoms of the gas

It is also called as 4th state of Matter

 GENERATION OF PLASMA
Gases at high temp. ionizes due to jumping of
outermost electrons from their orbital.

These electrons are in highly excited state. so

they have high energy content.

Some atoms also reach to their highest possible

energy levels.
 PLASMA ARC PROCESS (PAP)

PAP does not depend upon chemical

reaction between the gas & the work
material. So, it can be used on almost any
metal.

High velocity supersonic jet of plasma

issuing through a constricted orifice is used
for machining process.
 PAP has found its use mainly in the field of
welding and cutting.

Due to very high temp. almost any metal (SS,

Al alloys, titanium, nickel etc.) can be
machined using PAP

In L&T PAP is being used as a cutting process

known as PLASMA ARC CUTTING (PAC)
 PLASMA ARC CUTTING (PAC)

It involves severing of metal by melting a

localized area with a constricted arc &
removing the molten material with a high
velocity jet of hot, ionized gas (plasma)
issuing from the orifice.

It relies on heat generated from an arc

between the torch electrode & work piece.
 Principle Of Operation

PAC make use of DCEN with a constricted

transferred arc struck between a tungsten
electrode situated within the torch & the work
piece to be cut.

Pilot arc generated between electrode & nozzle

initiates cutting arc between electrode & work
piece using a pilot arc relay contact.
PLASMA arc cutting circuit
+

-
H.F.
generato -
r+
Direct
current Electrod
power e
supply
Resistor
Torch
Pilot Nozzl
arc
relay
e
contac
- t +

Work piece
 H.F. generator connected to the electrode &
nozzle initiates pilot arc and transfer it to main
arc through low resistance path.

The base metal is continuously melted by

intense and localized heat of arc and removed
by the jet like gas stream to form a narrow kerf
& smooth surface.
 Gases used in PAC

Any gas or gas mixture that does not

degrade the properties of the tungsten
electrode or work piece can serve as plasma
gas.

Ar, N2, H2, O2 and their mixture are

frequently used to serve the purpose.
 Quality of cut

Due to swirling of gas, arc cuts have a V

shaped included angle of 2-4 on one of the
cut edges.

Torch assembly must be properly done so

that bevel is on the scrap side of cut.
 Factors which affects the quality of cut are:-

Nozzle selection
Torch Assembly
Current
Variation in Gas pressure
Stand Off distance
Feed
 Factors which are considered while deciding
the quality of cut are:-

1. Surface smoothness.
2. Degree of parallelism of cut faces.
3. Dross adherence.
 PLASMA cutting equipment

Major equipments necessary for carrying

out cutting are:
1. Cutting torch
2. Power supply
3. Gas cylinders, regulators & flow meters.
4. Various controls of system.
 Equipments used in L&T

Cutting torch PT 15 plasma cutting

torch (P/N 996252)
Machine CNC Plasma cutting
Machine Union Carbide
CM-350
Power Supply PH601 plasma power
supply (P/N 677330)
 PCM-8 Cutting Outfit Package
1. PCC8 main control &
Plumbing Box(P/n 677764)
2. Omni Height Control with
Crash Guard Protection
4. H.F. Gen. assy. (P/N 677752)
5. Hoses & Cables
WC7 Water injection Pump Assy.(P/N 598484)
 Linde CM350 M/C

M/C is in the upperrange of midsize machines

with a great deal of patterned design
Basic structure is a gantry style with beam
spanning across two end trucks that ride on a floor
mounted rail system.
Accuracy & ease of operation are derived from a
rack & pinion drive system controlled by UCNC
system.
Here CM350 is in use whose specifications are
listed below:
cutting width 5258 mm
overall width 6550 mm
machine depth 2360 mm
carriage length 1584 mm
machine height 2390 mm
cutting table height 711 mm
cutting length multiples of 16' & one 8' ext.
torch capacity 8 gas & 2 plasma
speed range
gas 0-1270 mm/min
plasma 0-7650 mm/min
electrical supply 460/230 vac, 10/20 amp, 50/60 Hz, single ph
oxygen supply 200 psi max.
fuel gas supply 15 psi max.
air supply 80 psi min.
 CUTTING TORCH
Plasma cutting torch may be either manually
operated or Machine operated where travel
mechanism ill be automatic.

Torch consists of an electrode holder which

centers the electrode tip w.r.t. the orifice in the
constricting nozzle.

In L&T PT15 torch manufactured by union

carbide corporation, linde division, USA is in use.
 PT 15 TORCH

Designed for plasma water injection cutting.

Capable of carrying upto 750 amps DCSP
for cutting 3 mm to 76.2 mm thick MS, SS
& Al Plates.
Designed to eliminate double arcing, high
freq. leakage, & corrosion of parts.
Components of a PAC torch
Components of PT15 torch are:

1. Nozzle retaining cup(996230)

2. Nozzle assy.
3. Electrode tip (600236)
4. Tip holder (2075343)
5. Swirl baffle (2075341)
6. Contact ring assy. (996341)
7. Insulator body (996232)
8. Body assy. (996240)
9. O rings (86W99, 996527, 2064106, 86W85)
PT15 assembly
PT15 hose & cable assy.
Nozzle Assembly
 Specifications

current ranges
Nozzle Assy P/N Orificediameter material thickness Range amps

in. mm in. mm

XR nozzles

2075691 0.125 3.2 0.125"-0.75" 3-10 250

2075611 0.156 4 0.25-1 6-25 300-400

2075612 0.2 5.1 1"-2" 25-50 575-600

2075613 0.23 5.8 2"-3" 50-75 700-750

High current nozzle

2075587 0.25 6.4 3"-6" 75-100 800-1000

 Power Supply

PAC requires a constant current or drooping V-

A characteristics, relatively high voltage direct
current power supply.

OCV is generally twice the operating voltages.

Simplest form of power supply is of the fixed

output consisting of a transformer & rectifier.
 Operating voltage from 60 200V required
OCV range from 150 400 V

Here PHC 601 from L-TEC systems is in use

 Specifications (Power Supply)
Rated output
continuous duty 600amp@250vdc
100% duty 750amps@250vdc
output current range 200-750 amps
OCV 425 vac
input voltage 415V, 50 Hz, 3 Ph
input current
continuous duty 275amp@415vac
100% duty 340amp@415vac
power factor rating 85%

size
width 927 mm
depth 1105 mm
height 1245 mm
weight 990 kgs
VIEW OF POWER
SUPPLY
AUTOMATIC HEIGHT CONTROL
(AHC)
AHC system maintains a constant distance
between the torch nozzle & plate during the
cutting process regardless of variations in the plate
surface such as warpage.

In capacitive height control system, variation in

torch to plate distance is electronically sensed as a
change in capacitance.
 Due to underwater cutting technique, the
capacitance height control system is not
sufficient for plasma. So, VHC takes over
from capacitance system when plasma arc is
established.
Voltage height control system senses any
change in the arc voltage caused by variation
in the torch to plate distance.
PLASMA STATION WITH VHC
 PROBLEM
The main existing problem is the high width of kerf & taper
during cutting of SS plates.

Generation of Net after cutting

Due to non functioning of AHC, stand off distance depends

largely upon the skill of operator.

Task is to find the possible reasons for the existing problem

and to find the solution to this problem.
 OPERATING DATA IN USE
Plate Thickness CuttingSpeed(SS)
Nozzle assy Orifice Dia. (mm) Current (amps) (mm) mmPM

3.175 250 under 6.35 2540-8890

3.9624 400 6.35 4572

400 9.525 3048
400 12.7 2286

5.08 600 12.7 3048

600 19.05 1778
600 25.4 1143

RECOMMENDED ORIFICE DIA./AMPS

DIAMETER AMPS.

Material Thickness under 6.35 mm 3.175 250

Material Thickness 6.35 mm to 12.7 mm 3.9624 400
Material Thickness Over 12.7 mm 5.08 600
 Possible causes

Cutting speed could be too high

Standoff distance is not uniformly maintained due to
non-workingness of AHC
Swirling of gas is not proper
Faulty combination of nozzle assy. & electrode tip is
being used
Technical problem in AHC system.
Use of Duplicate Accessories for torch.
 Data after making few corrections

THK 14 MM

Parameter Before After

Kerf
Input kerf 9 mm 5 mm
Actual 7.5 mm 5 mm
Feed
Rapid 6500 mm/ min 6500 mm/ min
Cutting 2111mm/min 2300-2400 mm/min
Current 395 amp 350 amps
N2 PRESSURE 40-45 psi 30-36 psi
Standoff distance 7-8 mm 5-8 mm
Orifice dia. 3.96 mm 3.96 mm
THK 25 MM

Parameter Before After

Kerf

Input kerf 9.5 7 mm

Actual 8 7 mm

Feed

Rapid 6500 mm/ min 6500 mm/ min

Cutting 1250 mm/min 1250 mm/min

Current 400 amps 425 amps

N2 PRESSURE 38-46 psi 38-46 psi

Standoff distance 8 mm 8 mm

Orifice dia. 3.96 mm 3.96 mm

 RESULTS

Use the following accessories:

1. Nozzle assy. (ATTC) P/N 2075611/12/13
2. Swirl Baffle (ATTC) P/N 2075341
3. Electrode (ATTC) P/N 600236

Maintain proper feed rate, cutting speed & current

Use proper pressure of gas & coolant.
 The kerf width is reduced by 40 % after these
trials.

Successful Trials have been taken for 14 mm

& 25 mm THK SS sheets