The main advantages of thermal cutting are efficiency and accuracy. Compared to mechanical, this type of metal processing is also characterized by higher productivity. There are several varieties of thermal cutting. Moreover, in each case, special equipment is used.
Types of cars
Currently, the following main types of thermal cutting are used in production:
Machines designed to perform each of these operations can vary structurally, in terms of functionality and dimensions.
Plasma cutting
In this case, a portal thermal cutting machine is used, equipped with a special working body that creates an electric arc. It is called a plasmoid. The advantages of this type of metal processing include primarily high speed. Such machines are usually used when it is necessary to ensure the best or medium degree of accuracy of the cut. Some disadvantage of this method is the relative high cost of equipment.
Metals such as steel, aluminum and copper are cut on machines of this variety. They can function in two modes. Processing of metal with a thickness of less than 10 mm is carried out by a plasma jet. Thick sheets are cut with an arc of direct exposure. In the latter case, the workpiece being processed is part of an electrical circuit.
Oxygen cutting of metal
The main advantage of this technology is profitability. Equipment for oxygen treatment is cheaper than machines designed for plasma and laser. Most often this is an ordinary small thermal cutting machine, the price of which is low, moving on wheels. However, there are large autonomous gas machines designed for sheet processing in automatic mode (CNC). Sometimes enterprises use stationary machines with a cutter and a special movable niche. This equipment is very convenient in work and can be applied on the thickest sheets. However, it is, unfortunately, very expensive.
The advantages of oxygen cutting of metal, in addition to low cost, include the cleanliness of the seam, the simplicity of the technology, the absence of special requirements for the room in which the work is performed. The cons of gas cutting are considered to be high material consumption and not too high cutting accuracy.
Laser equipment
This type of gantry thermal cutting machine is mainly designed for metal processing with high precision. In addition, the laser gives a clean cut and can be used on both very thick and thin workpieces. The advantages of machines of this type, among other things, include versatility. It is possible to lay on them not only steel, but also plastic, wood, leather, fabric, rubber and other materials.
Also using this equipment volume laser cutting of metal is performed. Such machines are also used for the manufacture of complex flat elements of the decor of the interior and exterior.
The main disadvantage of portal machines with a laser head is considered high cost. In addition, not all types of metals can be cut on such equipment . For example, it is very rarely used for silver processing because of the high reflective qualities of the latter.
Combined machines
Nowadays, this type of equipment is often used at enterprises. The combined thermal cutting machine can be equipped with several carriages of various types: gas and plasma. Of course, such machines are expensive. However, at the same time, they allow you to perform a metal processing operation with high productivity, as quickly and efficiently as possible. Therefore, they usually pay off in a rather short period of time.
CNC equipment
Gantry technical machines can be controlled either manually or automatically. The latter variety is considered more convenient. In this case, a mini-computer with software is connected to the machine. Before starting work, the specialist introduces a special program into the control system, the purpose of which is automatic cutting according to the specified parameters. Machines of this type operate almost without operator intervention. An employee of the company ensures that there are no malfunctions when processing sheets.
The advantages of such equipment as a portal CNC thermal cutting machine include, first of all, a very high speed of work. The disadvantage of this type of machine is the need to use powerful ventilation systems designed to remove small metal particles formed during cutting. And, of course, special specialists are needed to service such equipment. Therefore, enterprises have to either hire new employees or retrain old ones.
Design features of a plasma machine
All machines of this type are divided into console and portal. The cantilever type thermal cutting machine does not have such a structural element as a table, and is cheaper. Gantry equipment is much more convenient to use and productive. The workpiece on these machines is fixed on the table with special elements, which ensures cleanliness and accuracy of the cut.
The design of such equipment as a CNC plasma machine includes:
- Apparatus for supplying voltage and compressed air. The latter is supplied under high pressure. In the process, the air is heated to a temperature of 20-30 thousand grams. and ionizes, as a result of which it becomes a very good electrical conductor and turns into a plasma.
- Plasma head.
- Cutting system.
- Devices for moving the head.
- Control system.
Design features of the gas machine
Equipment for cutting metal of this type is equipped with a special head, from which a stream of oxygen mixed with combustible gases escapes under pressure. Tables in gantry machines of this type have a special design that allows them to withstand high temperatures and loads from very heavy workpieces. As in plasma, such machines have a cutter, devices for moving it and a control system. Gas during operation is supplied from connected cylinders. Safety of cutting is ensured by special fire protection valves.
Laser machine design
Equipment of this type usually has not too large dimensions. As in other varieties of thermal cutting machines, all the working elements are fixed to them on a strong frame. The most important components of this type of equipment are a laser cutter and drives that ensure its movement in different planes. Also, the design of this equipment includes lubrication, cooling and smoke exhaust systems. The control panel for such machines is equipped with a liquid crystal display.
Basic selection options
When buying equipment such as a stationary machine for thermal cutting of metals, first of all pay attention to the width and length of its desktop. Also very important are indicators such as processing speed, positioning accuracy, maximum and minimum allowable metal thickness.
How to choose a laser machine
When buying such equipment, an important indicator is the possibility of using certain metals for cutting. In machines of this type, heads of different designs can be installed. Fiber laser cutters are mainly intended for cutting ferrous metals. The maximum thickness of workpieces for machines with such a head is 20 mm. Sometimes equipment of this type is also used for cutting metals with high reflectivity (copper, silver, brass). Using Slab CO2 heads, laser cutting of metal with only low reflectivity can be performed. Of color, such cutters can only be used on aluminum. Also, this particular type of heads is used for cutting leather, wood, plastic, etc. The maximum thickness indicator for workpieces for machines with such a head is 25 mm. Nd: Vag cutters are designed for processing ferrous and non-ferrous metals. Using them, you can cut workpieces with a thickness of not more than 4-5 mm.
In addition to the type of head, when choosing a laser machine, you need to pay attention to what kind of security system it is equipped with. Best of all, if the design of such a machine will include a special protective chamber. On machines of this configuration it is allowed to work without glasses.
The choice of a plasma machine
When buying such a machine, you need to pay attention to:
the maximum allowable thickness of the cut metal;
type of metal being cut;
the complexity of the configuration of the cut;
profitability in terms of electricity consumption.
What to look for when buying a gas machine
In this case, you should also look at the maximum allowable thickness of the part and the complexity of the configuration of the cut. Another important indicator when choosing an oxygen machine for metal processing is the type of photoelectric control. Some thermal cutting machines of this variety cut parts according to a drawing made by ink on white paper, others only according to copier drawings on a scale of 1x10.
Price for machines
The cost of equipment designed for thermal cutting depends on its variety, size and performance. The cheapest, as already mentioned, are oxygen devices for cutting metal. Prices for them can vary between 600-800 thousand rubles. Plasma devices cost a little more - 700-800 thousand rubles.
Prices for combined gas + plasma models range from 800-1200 thousand rubles. You can also purchase mini gantry machines of this type. They can cost about 300-400 thousand rubles. The most expensive type of equipment are laser machines for cutting metal. Prices for them, depending on size, range from 300-9000 thousand rubles.
As for the manufacturer, the most popular are SteelTailor units, as well as Alfateh from NPP Tekhmash.
Equipment intended for thermal cutting of metals, thus, may have a different design. Both the cost and the performance of the machine depend on the type of cutting head. The choice of a specific model depends primarily on the accuracy and speed with which it is necessary to cut, as well as on which metals it is intended to be used.