Company Profile
Hubei Meisar CNC Technology Co., Ltd focus on metal sheet and tube processing, specialized in developing, manufacturing distributing and servicing globally kinds of portable CNC plasma flame cutting machines, gantry CNC plasma and flame cutting machines, table CNC plasma and flame cutting machines, pipe CNC plasma and flame cutting machine, fiber CNC laser cutting machines which are using in metal sheet and tube cutting.
Why Choose Us?
Professional Team
Hubei Meisar CNC Technology Co., Ltd own a large number of specialists and outstanding technicians engaged in mechanical, electrical automation controlling technology, electronic information engineering and computer software.
Safety Assurance
Hubei Meisar CNC Technology Co., Ltd have had the international experience over 15 years on cnc plasma and flame cutting machines, have oversea distributor in Taiwan, India, Malaysia, Sri Lanka, Mexico etc, can offer local consulting. Sincerely thanks every friends' trust, looking forward to you becoming one member of we family.
Customization requirements
Hubei Meisar CNC Technology Co., Ltd is committed to build the brand of the high end but practical cnc cutting machines, with options of cutting way and cutting capacity.
Complete After-Sale Service
Meisar CNC is with a vision of 15 years and the frontiers of the cnc cutting machines manufacturing and related.
Related Product
What is Plasma Cutter?
Plasma cutting is a process that cuts through electrically conductive materials by means of an accelerated jet of hot plasma. Typical materials cut with a plasma torch include steel, stainless steel, aluminum, brass and copper, although other conductive metals may be cut as well. Plasma cutting is often used in fabrication shops, automotive repair and restoration, industrial construction, and salvage and scrapping operations. Due to the high speed and precision cuts combined with low cost, plasma cutting sees widespread use from large-scale industrial computer numerical control (CNC) applications down to small hobbyist shops.
Benefits of Plasma Cutter
More versatility
Plasma cutting can be performed on diverse types of metal. It uses an electric arc to cut any conductive metal like steel, iron, copper, brass, aluminum, stainless steel, and other durable materials. Plasma can also cut different materials stacked on top of one another with the fastest cutting speed. Techniques like oxyfuel can't duplicate this, which is why it's one of the best options for a variety of metalwork. The cuts a plasma cutter can create are also versatile, allowing you to bring your vision for your artwork or project to life.
Ease of use
Plasma cutters are portable and you can easily move this wherever the job demands. Some brands are so portable that just one person can easily handle this. As long as the operator of the plasma cutter is well-trained, it's a very safe and reliable solution for cutting metal.
Fast cuts
If you compare the cutting speed of a plasma cutter with any cutting tools, you'll find a plasma cutter is the winner since it's a time saver and a lot easier than other cutting equipment. A plasma cutter gets the jobs done in a quarter of the time of any other cutting tool. This tool doesn't need to be preheated before cutting. Thus, it saves cutting time, helping you to complete your project in no time at all.
Precision cut quality
It takes an experienced operator with a steady hand to really make a clean cut. Precision or accurate cutting is one of the major advantages of a plasma cutter, especially when it comes to cutting different shapes or angles with sheet metal. When discussing the question of what is plasma cutting, you'll find that this is one of the top benefits of this type of work.
Lower price
Plasma can cut things faster and with less waste, plus there is very little loss due to on-the-job injuries. This means the price comes down for the end user so it's a more cost-effective process than other cutting methods.
Piercing speed
This is where plasma really shines in comparison to oxyfuel. Many cutting applications require inside piercing. When piercing 15 mm metal with oxyfuel it must first be heated up to about 1000 degrees celsius and this takes upwards of 30 seconds. Since plasma doesn't need this step it can do the same piercing in less than two seconds. Less time equals less money charged to the end user.
Safety
Because this cutting process uses gas that is not highly flammable, it's a safer method than other processes. We always recommend working with our team of professionals though, who will ensure your metal is safely and accurately cut.
Types of Plasma Cutter
1.Conventional plasma systems - Typically use shop air as the plasma gas, and the shape of the arc is determined by the nozzle on the torch. Handheld systems fall in the conventional plasma system category, as well as applications where the materials being cut have a lower tolerance. While these types are common, they are less precise than the other form of plasma cutting.
2.Precision plasma systems - Use a variety of gases such as oxygen, nitrogen, or a mix of hydrogen/argon/nitrogen to achieve optimal cuts on a wide range of conductive materials. These types of systems are CNC controlled and are designed to produce the most precise cuts achievable using plasma. The torches and the designs they cut are more complex, and the shape of the arc is constricted to add precision.
Application of Plasma Cutter
Plasma cutters are widely used in metal fabrication to cut and shape metal sheets, pipes, and other materials. They are ideal for creating intricate designs and shapes with precision and accuracy.
Plasma cutters are commonly used in automotive repair to cut and remove damaged parts, such as exhaust pipes, frames, and body panels. They are also used to create custom parts and modifications.
Plasma cutters are used in construction to cut and shape metal beams, pipes, and other materials. They are ideal for creating precise cuts and angles for welding and joining.
Plasma cutters are used in demolition to cut and remove metal structures, such as bridges, buildings, and pipelines. They are ideal for cutting through thick metal quickly and efficiently.
Plasma cutters are used by artists to create intricate metal sculptures, wall art, and other decorative pieces. They allow artists to create unique designs and shapes with precision and accuracy.
Power supply - The plasma power supply converts single or three phase AC line voltage into a smooth, constant DC voltage ranging from 200 to 400VDC. This DC voltage is responsible for maintaining the plasma arc throughout the cut. It also regulates the current output required based on the material type and thickness being processed.
Arc starting console – The ASC circuit produces an AC voltage of approximately 5,000 VAC at 2 MHz which produces the spark inside of the plasma torch to create the plasma arc.
Plasma torch – The function of the plasma torch is to provide proper alignment and cooling of the consumables. The main consumable parts required for plasma arc generation are the electrode, swirl ring, and nozzle. An additional shielding cap may be used to further improve cut quality, and all the parts are held together by inner and outer retaining caps.
Process of Plasma Cutter
Here are 10 steps for proper plasma cutting:
Read the owner's manual
While it does take patience to wade through many pages of technical writing, most of us just underestimate the importance of doing so. Safety precautions should be memorized, and you should consult the manual with any question you have, no matter how small.
A plasma torch is just about one of the most dangerous tools a worker could operate. The Department of Labor Weekly Fatality/Catastrophe Report indicates that plasma cutter accidents happen at an alarmingly high frequency.
Button your shirt cuffs, pockets, and collar
While you know to wear proper safety gear like gloves, jacket, and flame-resistant clothing, you might forget to button your cuffs, pockets, and collar. No matter how flame-resistant your clothing is, if a stray fiber or strand on an unbuttoned cuff is exposed and catches a spark, it could lead to serious injury or death.
Shield your eyes with proper shade lenses
While this step should be in the owner's manual, it's especially crucial to your safety, so we're repeating it here. It's also important to make sure you aren't using a shade lens unsuited to the plasma cutter you intend to use. It can be hard to remember to switch to the proper shade lens when we switch machinery. Although you might not notice the difference, your eyes will, and your vision will degenerate over time.
Use ordinary compressed air
Contractors often choose bottled nitrogen because it costs less than bottled air. When cutting stainless steel, some also think nitrogen is better because it causes less oxidation.
The truth is that most plasma cutters use a hafnium electrode that functions best in an oxygen-rich environment. Hafnium electrodes will eventually evaporate, which causes plasma cutters to start misfiring and leave behind more dross until they can't cut at all. It's in every cutter's best interest to have hafnium electrodes last as long as possible - which means that compressed air is, in fact, better than nitrogen.
Brace your cutting hand
It's time to start cutting. The best way to trigger the pilot arc is by supporting your cutting hand with your off-hand, This gives you a great pivot for 180-degree movement, and also maintains a constant 1/16th to 1/8th inch standoff for cutting.
Trace your path (without pulling the trigger)
Tracing the cutting path before pulling the trigger is an underrated technique that is very reliable when it comes to plasma cutting, especially for longer cuts. It can create a smooth, continuous cut, rather than more unappealing start-and-stop cuts. One of the worst things you can do in the middle of a cut is stop and think about where you have to go next.
Make a sample cut
To make sure all of your settings are correct, make a sample cut on a metal of the same quality and thickness.
Know your thickness
For thin metals, a plasma cutter's pilot arc will punch right through to the other side. This means that you can start your cut with the electrode at 90 degrees to the metal.
For thicker metals, the plasma cutter will need some more space between the material; it's best to approach thicker metals at a 45 degree angle, which helps avoid the backlash of sparks. Once everything's under control, roll the torch to 90 degrees.
Watch the sparks
As you're cutting, you should watch the sparks from time to time. If sparks are shooting along the top of the metal, you're going too fast and need to slow down. At the proper speed, sparks should fly at 15 to 25 degrees opposite the direction of movement of the plasma cutter.
Mind the edge
Lastly, pay close attention to the edge of a metal when you're near the end of the cut, especially when using thicker metals. Just as you started your cut with a roll 45-to-90 degree roll, so you should end it that way, too. You'll want to roll the torch towards the final edge and pause to make sure you cleanly sever the metal at the end of the cut.
How to Maintain Plasma Cutter
Check the gas pressure
A low gas flow can lead the nozzle to melt in higher temperature. And you know heat depends on the pressure of the gas.
More pressure causes more heat. So it should be controlled. If you increase the pressure by more than five psi, then the electrode will wear faster and this creates the possibility of damage to the nozzle.
Also, if the pressure is lower than five psi, it will cause poor cut quality. So, it is best to follow the prescribed cutting chart while setting the gas pressure.
Maintain proper pierce height
For saving the plasma torch from damage and having the best cut quality, you must ensure the pierce height is perfect. You should maintain the torch-to-work distance, as well as initial pierce height, while cutting.
The proper pierce height of torch-to-work distance (during cutting) is 1.5 mm. And the initial pierce size, which means the distance set while triggering the torch or before descending, is 3.8 mm.
Clean the consumables when needed
Deposits of impurities, also grease, dirt, and metal dust can buildup in a different part of the plasma machine during daily use.
This can easily block the holes of the swirl ring or inner retaining cap, which lead the plasma arc to become skewed, and then you face low cut quality of your materials.
So, make sure to keep the parts as clean as possible. You can wipe down the piece with a clean towel whenever you remove these from the system.
Poor electrical connection? Check it out
A poor connection can inhibit the arc transfer established between the nozzle and electrode.
Where the arc transfer normally occurs within 100 milliseconds, a poor connection leads it to delay 10 seconds or more. And if given a chance to misfire, this also increases consumable wear.
It is best if you can connect the work cable to table ground directly from the power supply and after that connect the jumper cable from the table to the work piece. It's only for reducing excessive slag production that causes poor connection.
Use proper coolant flow
You have already seen what happens during low coolant flow. Electrodes can be damaged with rapid erosion. So, what to do for a proper coolant flow?
Check the coolant system filter to see if it's clogged with particles. Make sure it's not. Do a flow test to ensure the flows are consistent with the oem specifications.
Avoid adding circular lead-out
Proper management of gas pressure at the beginning and end of the cut is tricky but important to save the consumables from a shortened life. At the end of cutting holes, a lead-out occurs when you shutdown the arc.
You can use nesting software that can include a little over burn to clean up the hole at the end of the cut. Proper programming of the cnc can eliminate lead-out at the end of the cut.
Moreover, always try to shut off the plasma in the scrap area.
How Does a Plasma Cutter Work?
The plasma cutting process is a thermal cutting method. This means that it uses heat to melt the metal instead of mechanically cutting it.
The overall mechanics of the system is always the same. Plasma cutters use compressed air or other gases, such as nitrogen. Ionisation of these gases takes place to create plasma.
Typically, the compressed gases come into contact with the electrode and then ionise to create more pressure. When the pressure builds up, a stream of plasma is pushed towards the cutting head.
The cutting tip constricts the flow to create a stream of plasma. This is then subjected to the workpiece. As plasma is electrically conductive, the workpiece is connected to the ground through the cutting table.
As the plasma arc contacts the metal, its high temperature melts it. At the same time, the high-speed gases blow away the molten metal.
Optimization Techniques for Plasma Cutting
The plasma exits the nozzle with a clockwise rotation as a result of the current generating a magnetic field. This should be considered when planning a cutting operation. For best quality on external edges, configure the direction of movement so the torch travels in a clockwise direction, cutting on the right side of the plasma. When cutting holes, the travel should be counterclockwise.
Edge squareness is optimized by remembering that the plasma has a bulb form. Thus the widest part should be positioned at the midpoint of the plate or sheet thickness. A torch that's too high or too low will put an angle on the edge.
When the travel speed is too high the plasma tends to drag against the surface, producing a characteristic edge pattern. There will also be fine dross on the bottom edge and spatter on the top. If the speed is too low this will be evident by globular dross on the bottom surface.
Arc generation wears the nozzle, and this should be considered a consumable. Always replace nozzles and electrodes as a pair.
Ideal Materials for Plasma Cutting
Plasma cutting's number one job is slicing through metal. Some of the most common metals cut with plasma are mild steel, stainless steel, and aluminum. All three materials are excellent conductors, and they each have melting points lower than the maximum temperature of a plasma torch. Below is more information on each of these compatible metals.
Mild steel
One of the best benefits of mild steel is its availability. Some metals are not widely available or cost exorbitant amounts to work with-mild steel is relatively accessible. On top of that, mild steel is a strong and versatile material, making it a good starting place for a variety of projects.
While handheld plasma cutters can slice through mild steel up to an inch thick, you should rely on industrial machines to tackle ferrous and non-ferrous metals over this thickness.
Stainless steel
Stainless steel is another material well-suited for plasma cutting. As one of the most corrosion-resistant materials on the market, stainless steel is an extremely popular choice for many applications. With a high strength-to-weight ratio, you'll find stainless steel in architectural, marine, and other industrial applications.
While stainless steel has a higher melting point than mild steel or aluminum, plasma cutting can still handle the task without a problem.
Aluminum
Aluminum, a material common in aerospace and automotive applications, is a perfect candidate for plasma cutting. It has the lowest melting point of any of the other metals we've discussed so far, making it extremely easy to cut through with a plasma torch.
Aluminum has high reflectivity and low thermal expansion, making it work well in architectural projects. Plus, plasma cutting can easily slice aluminum into unique shapes for architectural design.
Our Factory
Ubei Meisar CNC Technology Co., Ltd international department have oversea branches distribute in China Taiwan, India, Malaysia, Sri Lanka, Mexico etc. The High quality cutting equipment had been used all over the world, say, German, Taiwan, Finland, Norway, Russia, India, Indonesia, Thailand etc, the application involved machine tools, machinery, ships, chemical, petroleum, and other fields.
FAQ
China Make
|
|
LGK-63IGBT |
LGK-100IGBT |
LGK-160IGBT |
LGK-200IGBT |
|
Rated input capability |
9.9KVA |
14.5KVA |
26.3KVA |
34.9KVA |
|
Rated output current |
63A |
100A |
160A |
200A |
|
Rated output voltage |
105.2 |
120V |
144V |
160V |
|
Rated duty cycle |
60% |
100% |
100% |
100% |
|
Current adjusting range |
30-63A |
30～100A |
40～160A |
40～200A |
|
Max cutting capability |
20mm |
40mm |
50mm |
65mm |
|
Piercing capability |
12mm |
15mm |
20mm |
25mm |
|
Plasma air |
Compressed air |
Compressed air |
Compressed air |
Compressed air |
|
Torch cooling method |
Air-cooling |
Water-cooling |
||
|
Dimension(L×W×H) |
695*320*580mm |
695×320×580mm |
800×380×610mm |
800×380×810mm |
|
Weight |
32Kg |
51Kg |
73Kg |
90Kg |
USA Make
|
Model |
PMX45 |
PMX85 |
PMX105 |
PMX125 |
MAXPRO200 |
|
Rated Input Capacity (KVA) |
5.95 |
12.2 |
16.8 |
21.9 |
33 |
|
Rated Output Voltage (VDC) |
132 |
143 |
160 |
175 |
50-165 |
|
Current Range (A) |
20-45 |
25-85 |
30-105 |
30-125 |
40-200 |
|
Current Range (%) |
50-100 |
60-100 |
80-100 |
100 |
100 |
|
Max Cutting Thickness (mm) |
25 |
38 |
50 |
57 |
75 |
|
Piercing Thickness (mm) |
12 |
20 |
22 |
25 |
32 |
|
Plasma Gas |
Air/N2 |
Air/N2 |
Air/N2 |
Air/N2 |
Air/N2/O2 |
|
Torch Cooling Method () |
Air |
Air |
Air |
Air |
Water |
|
Machine Size(L*W.*H) (mm) |
426*172*348 |
500*234*455 |
671*427*655 |
592*274*508 |
1020*690*1050 |
|
Net Weight (Kg) |
17 |
32 |
45 |
45.2 |
335 |
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