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Recent Technology Developments

In the last seven years, developments in plasma cutting technology have come at a fast pace. The latest revision on high-definition machines is their full integration with the CNC machines they are coupled with. New CNCs have touchscreen accessibility, minimizing the number of buttons involved in operating a plasma cutting machine and making operation as simple as almost any Windows?-based software. Operator training has been simplified on even the largest, most complex CNC plasma cutting machines.

The operator’s job also has been made easier with improvements in auto-calibrating height control functionality. The operator does not need to make adjustments as the consumable parts in the torch wear out.

Hole cutting has been improved with a large database of information in the CAM software that automatically recognizes CAD features and implements the best possible cut path and plasma cutting parameters, including on-the-fly shield gas changes that nearly eliminate the normal taper found in plasma-cut holes on steel (see Figure 3). This process is transparent to the machine operator and system programmer, eliminating the need for them to be experts.

Improvements in cut-to-cut cycle times have been incorporated into CAM software. The software automatically recognizes areas of a full cutting nest (multiple parts) and modifies the traverse time, torch retract time, and gas preflow time to decrease production times and improve product throughput.

Nesting software now applies the lead-in points in the most effective way to avoid traversing over areas prone to collisions with previously cut parts.

Improved plate beveling software has simplified the integration and operation of a bevel head with XY CNC cutting machines. This advancement, again associated with the system’s CAM software, saves much of the programmer/operator trial-and-error testing that has always been necessary to hold the best tolerances on plate edge beveling applications, such as weld prep.

Very new vented nozzle and gas mixing technology has helped improve stainless steel edge quality. Edges are squarer, shiny, and weldable.

Air plasma cutting systems from the major manufacturers also improved dramatically in terms of cut quality, consumable life, and duty cycles. These systems, primarily designed for portable and in-shop hand-held cutting applications, now are available with quick-change mechanized torches and interface easily to a variety of lower-cost CNC machines. Systems are available from a 30-amp, toaster-sized unit that operates on 120-V household current to sever materials up to 0.5 in. thick, to a 125-amp, 100 percent duty cycle industrial unit that can sever 2.25-in. materials. Both portable systems can be used with a hand torch or can be mechanized for a variety of automated cutting applications.

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