Information For the Manufacturing Engineer

As a manufacturing engineer one must be familiar with all the available manufacturing processes. In this article we will be discussing water jet cutting and how it can be used to improve your manufacturing process. Waterjet cutting at its simplest form is a jet of water at a very high pressure that abrasively removes material. This water usually has an abrasive material such as Garnett added to aid in the abrasive material removal qualities.

It works by pressurizing water up to 60,000 psi, and forcing it through a tiny opening Waterjets are capable of cutting a variety of materials with CNC accuracy. Typical part tolerances range from between 0.005 and 0.010 of an inch. When small amounts of abrasive particles, such as garnet, are mixed into the jet stream, the resulting "abrasive waterjet" can cut virtually any hard material such as metal, composites, stone and glass.

Waterjet Cutting vs. Lasers
Laser cutting is a very productive process and certainly has its place. However, Waterjets do have several advantages over lasers:

There are no thickness limitations. A typical 1500 watt CO2 laser is limited to about .625" thick steel plate. There are no problems cutting with reflective materials such as Brass, Copper and Aluminum. There is no heat output, so there is no heat-affected zone (HAZ). Waterjets can cut materials, which are heat sensitive such as plastics, rubber or composites.

Waterjet vs. Plasma
Plasma removes material around 5800 deg f. leaving a large heat-affected zone. The surface finish of plasma generally is very course with a lot of slag. This slag requires secondary operations to remove where water jet cutting does not. Abrasive Waterjets have no thickness limitation, and can be much more closely nested.

What tolerances can we expect from waterjet cutting?
The accuracy you will get Typically +/- .010" but depending on part size and part thickness.

How thick can it cut?
Typical waterjet's can cut up to 8.00" in thickness depending on material type and hardness.

What materials cannot be cut?
Almost any material can be cut by water jet. There are some exceptions that can prove to be difficult; these materials tend to be laminated in construction. Test cuts have resulted in delaminating.

How thick is the Kerf?
The Kerf is about 10% of the diameter of the cutting orifice. If a .040" diameter tip is used Kerf is around .043" in diameter.

What is the minimum radius/ diameter that can be cut?
The radius limitations are dependent on the diameter of the orifice being used and are equal to the Kerf diameter. Using a .040" diameter tip the minimum radii and hole diameter will be around .043".

What taper can I expect?
The taper you get is a function of the cut speed. However, the worst taper you will get will be equal to the maximum Kerf width at the top (example: 0.043") and 0.000". At the bottom. As you slow down the taper will be reduced until you get parallel sides.

What fixturing is required?
Since the force exerted on the work piece is very small (under 5 lbs. for average cuts), the need for very large, stiff fixtures is eliminated.

For more information on waterjet cutting services and how they can benefit your manufacturing production visit http://www.e-bti.com.

Brent Cohagan
President
Cohagan Engineering, Inc.
http://www.CohaganEngineering.com

Article Source: http://EzineArticles.com/?expert=Brent_Cohagan

Purchasing Plasma Cutters

Plasma cutters are an important tool to have when it comes making sure you have the right automotive service equipment to get repairs done right. Like mig welders, this equipment uses electricity and gas to work, but that's where the similarities end. If you're looking to buy plasma cutters for your home shop or commercial garage, this article will explore a few things you should know before making a final purchasing decision.

Types and Features of Plasma Cutters

This type of automotive service equipment comes in three main types:

Compact - Noted for high power in a small, portable package, compact machines like these run off a standard 120V AC outlet, making them ideal for repairs on the go and onsite repairs. They cut everything from aluminum and stainless steel to carbon steel with ease and will remove spot welds almost instantly.

This style also uses a basic air compressor rather than requiring special gases and classes to haul it from place to place. Quality models will come with fans to keep everything cool and extend the life of the machines, built-in regulators with air reducers for total control, electrodes of various lengths, and different nozzles.

Low Amp Plasma Cutters - Low amp automotive service equipment models are similar to mig welders in the fact that they run off either 120 or 230V outlets. You can't beat this type of machine when it comes to cutting stainless, carbon steel, or aluminum, or removing spot welds. They also have built in pressure regulators, easy-to-use control panels, and fans to keep them cool. Larger wheels ensure that they move around far more easily and, because they run cooler, these machines won't over heat and damage the metal. For ease of use, look for models with compact handles, long tips, and longer nozzles, which are designed specifically for tight areas.

High Amp Styles - This type of plasma cutter runs upwards of 85 amps and weighs in at almost 100 lbs. Generally, thought of as stationary automotive service equipment, this style is available in 'engine driven' models or with a 'valet style' undercarriage for improved maneuverability. Machines that include VORTECH technology and dual winding technology give you a fast arc, better cutting speed, and improved performance with superior cutting abilities.

Features such as quick disconnects make it easy to remove and change torches while LED panels and indicators make the system easy to read and control. Other features to watch for include Parts-In-Place and lockout circuits for improved safety. For increased precision, particularly with repetitive or difficult cuts, select plasma cutter models with a CNC/Robotic interface.

Use & Application of Different Types of Plasma Cutters

Once you're aware of the types of plasma cutters you can choose from, you'll need to weigh the benefits of each style in order to determine which type is best for you.

Compact plasma cutter models are ideal for on site repairs of lighter metals of 3/8" or less in thickness. This means that those in auto body, farm, hobby, HVAC, and sheet metal fabrication absolutely love these machines. Additionally, since they run on 110V outlets, you won't be fighting to find somewhere to plug them in either.

Low amp machines are ideal for those industrial uses such as HVAC, light plate, and sheet metal fabrication. They make quick work on metal up to 3/4" thick and have winding technology, lower dross levels, and quick arc transfer rates for easy starts and fast restrikes so that you find it easy to work on even expanded metal.

If you'll be cutting metal up to 1 1/4" thick, you'll definitely need to look at high amp plasma cutters. This style of automotive service equipment is ideal for the most intense, industrial situations. In fact, this style is a favorite model for those working in fabrication, maintenance, and other heavy-duty applications.

Best Plasma Cutters Brands

Lincoln, Thermal Dynamics, and Marquette are just some of the best brands of plasma cutters you can find on the market. However, the reason why these brands have earned that title is far more important.

Warranty is an important aspect of any quality automotive service equipment brand. You want to be sure that the style of machine you purchase comes with at least two years worth of parts. This is vital since these cutters can be extremely expensive to repair. Also, be sure to go with a brand that has been around for awhile in order to improve the likelihood that you'll be able to get parts 10 or 15 years down the road.

ISO certification is also important when identifying quality brands. This system ensures that each machine meets strict industry standards and is tested before it ever leaves the plant. The plant itself is assessed and tested on a regular basis to ensure that it meets standards from start to finish.

Most importantly, make sure that you only purchase from a reputable dealer who offers quality equipment at a competitive price. This will ensure that you get the automotive service equipment that you ordered without worrying that the price is inflated, or that the certification and brand has been faked. You'll get quality equipment and quality customer service, and that's worth the time you take to research machines and dealers.

Chris Harmen is a writer for ASE Deals, America's top choice for automotive service equipment, including plasma cutters, car lifts, motorcycle lifts, welders, auto shop equipment and air compressors. ASE Deals offers competitive prices on all tools and repair equipment.

Article Source: http://EzineArticles.com/?expert=Chris_A._Harmen

CNC plasma-arc cutting power source

ESAB Cutting Systems has launched a CNC plasma-arc cutting power source that provides high-speed cutting of materials from 0.5mm to 100mm.

The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.

The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.

High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.

Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.

Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.

Cutting and marking operations can be carried out with the same consumables.

The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.