Lab Report Manufacturing Process-III

Experiment # 9

a) To understand the working principle and basic operating parameters of plasma arc cutting
machine.
b) To set work piece home and perform dry runs for different cutting profiles (straight cut,
circular, rectangular and triangular cuts).

9.1) Problem Statement:

Plasma is defined as a ”collection of charged particles containing about equal numbers of positive ions and
electrons and exhibiting some properties of a gas but differing from a gas in being a good conductor of
electricity. Regardless of what’s going on inside a plasma stream, the way to cut metals with it is pretty
straightforward. That’s why we move forward to plasma arc cutting.

9.2) THEORY:
9.2.1) Plasma arc cutting machine?
The plasma arc cutting process cuts metal by melting a section of
metal with a constricted arc. We use inert gases to form the arc as H2, He, N2 etc. A high velocity jet flow
of hot ionized gas melts the metal and then removes the molten material to form a kerf. The basic
arrangement for a plasma arc cutting torch, similar to the plasma arc welding torch.

Fig: Plasma Arc Cutting Machine

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Plasma Unit Compressor

9.2.2) Plasma arc cutting machine operation principle:

All plasma torches constrict the arc by passing it through an
orifice as it travels away from the electrode toward the workpiece. As the orifice gas passes through the
arc, it is heated rapidly to a high temperature, expands and accelerates as it passes through the constricting
orifice. The intensity and velocity of the arc plasma gas are determined by such variables as the type of
orifice gas and its entrance pressure, constricting orifice shape and diameter, and the plasma energy density
on the work.

9.2.3) Working table range:

Following ranges of working table are as:
 X= 50 inches
 Y= 100 inches
 Z= 6 inches
* Maximum 35 mm thick plate is cut
*we use oxylene flame
*The tip of tool is of Cu or brass.
*Maximum 1000A current in plasma unit
*Max 80 psi pressure

9.3) Advantages of plasma arc cutting machine:

There are many advantages for the plasma arc cutting process:

 small risk of changing the shape of the metal (called distortion)

 precise cutting
 slag-free cuts when working with aluminum, stainless steel and carbon steel
 works in all positions
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 fast process
9.4) Safety Instructions:
 The Experiment will be stopped immediately if safety instructions are not properly followed.
 Eye protection is necessary for the students in the work area
 Lab coats are included in compulsory clothing
 Students must clean the equipment when experiment is completed with the cleaning brush and tools
must be placed back to the tool kit

9.5) References:
 http://weldguru.com/plasma-arc-cutting/
 http://www.esabna.com/us/en/education/blog/what-is-plasma-cutting.cfm