How to extend the life of plasma cutting machine consumables
Summary of 15 tips to extend the service life of plasma cutting machine consumables
Plasma consumables in the maintenance cost of CNC plasma cutting machines are a problem that customers are very concerned about. CNC plasma cutting machine is one of the types of CNC cutting machine, also
It is a kind of equipment with a large one-time investment. Whether it is the world’s top ion cutting machines such as the United States Hypertherm, Fermat, or Germany Klebe, although they have good cutting quality, the problem of consumables cannot be underestimated. How to take effective methods to reduce losses is also a cost-saving method.
An effective means! As long as you pay attention to the problems mentioned in this article, you can generally improve the service life and maintenance cost of the gantry CNC plasma cutting machine to a large extent. Here are some commonly used methods to reduce the cost of plasma consumables as much as possible:
1、Use a reasonable cutting height
According to the requirements of the instruction manual, use a reasonable cutting height, which is the distance between the cutting nozzle and the surface of the workpiece. When perforating, try to use a value slightly higher than the perforation height in the parameter table.
2、Ensure the correct air pressure and flow rate of the plasma
The correct gas pressure and flow of the plasma are very important to the service life of consumables. If the air pressure is too high, the life of the electrode will be greatly reduced; if the air pressure is too low, the life of the nozzle will be affected.
3、Do not overload the nozzle
Overloading the nozzle (that is, exceeding the operating current of the nozzle) will quickly damage the nozzle. The current intensity should be 95% of the working current of the nozzle. For example, the current intensity of a 100A nozzle should be set to 95A.
4、The thickness of the perforation should be within the allowable range of the machine system
The cutting machine cannot perforate the steel plate that exceeds the working thickness. The usual perforation thickness is 1/2 of the normal cutting thickness (below 100A). For example, the 100A system is set to cut 1 inch (approximately 25mm) carbon steel. This system perforates The thickness should be 0.5 inches (approximately 12.5mm).
5、Keep the plasma gas dry and clean
The plasma system needs dry and clean plasma gas to work normally. Dirty gas is usually a problem with the gas compression system, which will shorten the service life of consumable parts and cause abnormal damage. The method to test the gas quality is to set the cutting torch in the test state and place a mirror under it to consume the gas in the cutting torch. If water vapor and mist appear in the mirror, you need to find out the reason and correct it.
6、Cutting should start from the edge
Start cutting from the edge as much as possible, instead of perforating cutting. Using the edge as the starting point will extend the life of the consumable parts. The correct method is to directly aim the nozzle at the edge of the workpiece before starting the plasma arc.
7、Reduce unnecessary “arc starting (or arc guiding) time
The consumption of nozzle and electrode is very fast during arc starting. Before starting, the cutting torch should be placed within the walking distance of the cutting metal.
8、Avoid elongation and expansion of the plasma arc
If the plasma arc can only be stretched and expanded to reach the surface of the workpiece, the plasma arc will produce such stretching and expansion at the beginning and end of the cutting, which will cause abnormal damage to the nozzle. If the correct edge start technique is used, the appropriate “arc breaking” signal time is selected,This problem can be avoided.
9、Apply splash-proof chemical paint on the protective shell
The splash-proof chemical coating helps to reduce the buildup of slag on the protective shell. But be sure to remove the protective shell from the torch before applying splash-proof paint.
10、Clear the gas after replacing consumables
After replacing the consumable parts or after a long period of shutdown, the gas should be cleared (2-3 minutes is appropriate) to retain water and mist to be discharged from the cut.
11、Remove the slag on the protective shell
The slag on the protective shell of the cutting torch should be removed frequently, otherwise, the slag will cause a destructive heavy plasma arc.
12、Try to keep the cutting torch and consumable parts clean
Any dirt on the cutting torch and consumable parts will greatly affect the function of the plasma system. When replacing consumable parts, place them on a clean flannel, check the connection ribs of the cutting torch frequently, and clean the electrode contact surface and nozzles with hydrogen peroxide cleaner.
13、Remove the oxides on the air or oxygen nozzles
When air or oxygen plasma is selected, the oxide will be deposited in the nozzle, which will affect the airflow and reduce the life of consumable parts. Wipe the inside of the nozzle with a clean flannel to eliminate oxides.
14、Use softened water to inject the cutting torch
Hard water will cause metal impurities to precipitate on the nozzle ring, which will affect the airflow, reduce the quality of the torch and shorten the life of consumable parts.
15、Check airflow and coolant flow every day
One of the most common reasons for cutting torch damage is the lack of cooling flow. It is necessary to check the airflow and air pressure (if air-cooled) or coolant (if water-cooled) to the cutting torch frequently. If there is insufficient airflow or leakage, shut down immediately. Troubleshoot.