YMCA University Of Science And

Technology, Faridabad
Plasma Arc Machining
Presented By:-
Navin Vashisth
Manoj Kumar
Presented To:-
Dr. Tilak Raj
YMCAUST,
Faridabad
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Content
2
Plasma Arc Machining
Working Principle of PAM
Process Details of PAM
Various type of Plasma arc cutting
Process Variable
Advantages of PAM Process
Disadvantages of PAM Process
Application of PAM


8/13/2014 Plasma Arc Machining
Plasma Arc Machining
Plasma Arc Machining is a process that is used to cut
steel and other metal of different thicknesses using a plasma
torch.
In this process, an inert gas in compressed form is
blown from the nozzle with very high speed; at the same
time an electrical arc is formed through that gas with
tungsten electrode turning some of that gas to plasma.
The plasma is sufficiently hot to melt the metal being
cut and moves sufficiently fast to blow molten metal away
from the cut.

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In this process gases are
heated and charged to
plasma state. Plasma state
is the superheated and
electrically ionized gases at
approximately 10000C
These gases are directed
on the workpiece in the form
of high velocity stream.
Working principle and
process details are shown in
Figure 5. Figure 5 : Working Principle and
Process Details of PAM
Working Principle of PAM
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Plasma Gun
Gases are used to create plasma like, nitrogen, argon,
hydrogen or mixture of these gases. The plasma gun consists of a
tungsten electrode fitted in the chamber. The electrode is given
negative polarity and nozzle of the gun is given positive polarity.
Supply of gases is maintained into the gun.
A strong arc is established between the two terminals anode
and cathode. There is a collision between molecules of gas and
electrons of the established arc. As a result of this collision gas
molecules get ionized and heat is evolved. This hot and ionized gas
called plasma is directed to the workpiece with high velocity. The
established arc is controlled by the supply rate of gases.
Process Detail of PAM
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Power Supply and Terminals
Power supply (DC) is used to develop two terminals in the
plasma gun. A tungsten electrode is inserted to the gun and made
cathode and nozzle of the gun is made anode. Heavy potential
difference is applied across the electrodes to develop plasma state of
gases.
Cooling Mechanism
As we know that hot gases continuously comes out of nozzle
so there are chances of its over heating. A water jacket is used to
surround the nozzle to avoid its overheating.
Cont.
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Tooling
There is no direct visible tool used in PAM. Focused
spray of hoot, plasma state gases works as a cutting tool.
Workpiece
Workpiece of different materials can be processed by PAM
process. These materials are aluminium, magnesium, stainless
steels and carbon and alloy steels. All those material which can
be processed by LBM can also be processed by PAM process.
Cont.
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VARIOUS TYPE OF PLASMA ARC CUTTING
Conventional Plasma Arc Cutting
In Conventional Plasma Arc
Cutting, the arc is constricted by a
nozzle only; no shielding gas is added.
Generally, the cutting gas is
tangentially injected the electrode. The
swirling action of the gas causes the
cooler portions of the gas to move
radially outward, forming a protective
boundary layer on the inside of the
nozzle bore. This helps prevent
damage to the nozzle and extends its
life. Electrode life is also improved.
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Air Plasma Arc Cutting
Air plasma arc cutting was
introduced in early 1960s for
cutting mild steel. Oxygen in the
air provides additional energy
from the exothermic reaction with
molten steel, boosting cutting
speeds about 25 percent. Although
this process can also be used to
cut stainless steel and aluminum,
the cut surface will be heavily
oxidized and thus can be
unacceptable for some
applications.
Dual-flow PAC is a slight
modification of conventional PAC It
incorporates most of the features of
conventional PAC but adds a secondary
shielding gas around the nozzle. The
cutting gas is usually nitrogen the
shielding gas is selected according to the
metal to be cut. Cutting speeds are
slightly better than those of conventional
PAC on mild steel, but the cut quality is
not acceptable for some applications.
Cutting speed and quality on stainless
steel and aluminum are essentially the
same as with conventional PAC.
Dual-flow Plasma Arc Cutting
Underwater Plasma Arc Cutting
Underwater PAC is suited to numerically(NC) shape cutting
and produces a noise level of 85dBA or less under normal operating
conditions. In comparison,conventional PAC typically produces
noise levels in the range of 105 to 115 dBA. Underwater cutting also
nearly eliminates ultraviolet radiation and fumes. Steel plate being
cut is supported on a cutting table with the top surface of the plate 2
to 3 inches underwater. Advice that locates the submerged top
surface of the metal is vital to the fully automated underwater PAC
process. Height control is maintained by a sensor that monitors arc
voltage. Cutting speed and quallity are comparable to those attained
with water injection PAC. Note that it is hazardous to cut aluminium
under water. Hydrogen generated by the process can be trapped
under the plate, creating the potential for explosion.
Underwater Plasma Arc Cutting
Process Variables
Key Process Variable
Current 15 to 400 A
Cutting Speed 200 to300 mm/min
Torch Height 2.54 mm to 7.72 mm
Cutting oxygen pressure 1.2 Mpa
Preheat oxygen pressure 1.0 Mpa
Voltage Range 150 to 400 V
Cutting Temperature 10000 C to 14000
C
Kerf Width 5mm to 28mm
CUT QUALITY
Factors affecting quality of a cut include surface smoothness, kerf
width, kerf angle, dross adherence, and sharpness of the top edge.
These factors are affected by the type of material being cut, the
equipment being used, and the cutting conditions.

Plasma cuts in plates up to approximately 75 mm thick may have a
surface smoothness very similar to that produced by oxyfuel gas
cutting. On thicker plates, low travel speeds produce a rougher surface
and discoloration. On very thick stainless steel, 125 to 180 mm in
thickness, the plasma arc process has little advantage over oxyfuel gas
powder cutting.

Kerf widths of plasma arc cuts are up to 50 mm. For example, a typical
kerf width in 25 mm stainless steel is approximately 5 mm. Kerf width
increases with plate thickness. A plasma cut in 180 mm stainless steel
has a kerf width 28 mm.

Process Variables
Cont..
The plasma jet tends to remove more metal from the upper part of the
kerf than from the lower part. This results in beveled cuts wider at the
top than at the bottom. A typical included angle of a cut in 25 mm steel
is four to six degrees. As Speed Increase Angle Increase.

Dross is the material that melts during cutting and adheres to the
bottom edge of the cut face. With present mechanized equipment,
dross-free cuts can be produced on aluminum and stainless steel up to
approximately 75 mm thickness and on carbon steel up to
approximately 40 mm thickness.

Top edge rounding will result when excessive power is used to cut a
given plate thickness or when the torch standoff distance is too large. It
may also occur in high-speed cutting of materials less than 6 mm thick.

METALLURGICAL EFFECTS
During PAM, the material at the cut surface is heated to its melting
temperature and ejected by the force of the plasma jet. This produces a
heat-affected zone along the cut surface, as with fusion welding
operations. The heat not only alters the structure of the metal in this
zone but also introduces internal tensile stresses from the rapid
expansion, upsetting, and contraction of the metal at the cut surface.

The depth to which the arc heat will penetrate the workpiece is
inversely proportional to cutting speed. The heat affected zone on the
cut face of 25 mm thick stainless steel plate is 0.08 to 0.13 mm.

Because of the high cutting speed on stainless steel and the quenching
effect of the base plate, the cut face passes through the critical (650
degree C) temperature very rapidly. Thus, there is virtually no chance
for chromium carbide to precipitate along the grain boundaries, so
corrosion resistance is maintained. Measurements of the magnetic
properties of Type 304 stainless steel made on base metal and on
plasma arc cut samples indicate that magnetic permeability is
unaffected by arc cutting.
Cont.
The heat-affected zones in aluminum are deeper than those in stainless
steel plate of the same thickness. This results from the higher thermal
conductivity of aluminum. Micro hardness surveys indicate that the
heat effect penetrates about 5 mm into 25 mm thick plate.

Aluminum alloys of the 2000 and 7000 series are crack-sensitive at the
cut surface. Cracking appears to result when a grain boundary eutectic
film melts and separates under stress. Machining to remove the cracks
may be necessary on edges that will not be welded.

Hardening will occur in the heat-affected zone of a plasma arc cut in
high carbon steel if the cooling rate is very high. The degree of
hardening can be reduced by preheating the workpiece to reduce the
cooling rate at the cut face.

Various metallurgical effects may occur when long, narrow, or tapered
parts, or outside corners are cut. The heat generated during a preceding
cut may reach and adversely affect the quality of a following cut.

MRR and Surface Roughness
MRR in g/s Surface Roughness in m
These are the experimental
results for stainless Steel
Power Supplies control
PAC requires a constant-current or drooping volt-ampere
characteristic, relatively high-voltage direct-current power supply.
To achieve satisfactory arc starting performance, the open circuit
voltage of the power supply is generally about twice the operating
voltage of the torch. Operating voltages will range from 50 or 60
volts (V) to over 200 volts (V), so PAC power supplies will have
open circuit voltages ranging from about 150 to over 400 volts.
Cutting Controls
For mechanized cutting, starting and stopping the cutting arc can
be manual by pushbutton or automatic by the motion controls of
the system. Cutting controls can also sequence the entire
operation, including varying the gas flow and power level if
necessary.
Plasma Arc Controls
Motion Control
A variety of motion equipment is available for use with plasma cutting
torches. This can range from straight-line tractors to numerically-controlled
or direct computer-controlled machines with parts nesting
capabilities. Plasma cutting equipment can also be adapted to robotic
actuators for cutting other than flat plates.
Environmental Controls
The plasma cutting process is inherently a noisy and fume generating
process. Several different devices and techniques are available to control and
contain the hazards. One commonly used approach to reduce noise and fume
emissions is to cut over a water table and surround the arc with a water
shroud. This method requires a cutting table filled with water up to the work-
supporting surface, a water shroud attachment to go around the torch, and a
recirculating pump to draw water from the cutting table and pump it through
the shroud. In this case, a relatively high (55 to 75 L) water flow is used.
Another method, underwater plasma cutting, is also in common use.
With this method, the working end of the torch and the plate to be cut are
submerged under approximately 3 in. (75 mm) of water. While the torch is
underwater but not cutting, a constant flow of compressed air is maintained
through the torch to keep water out.
Cont
Advantages of PAM are given below :
It gives faster production rate because of its Rapid Cutting Speed.
Very hard and brittle metals can be machined.
Wide Range of Material and Cutting Speed can also be performed
easily
Small cavities can be machined with good dimensional accuracy.
This Process is Easy to Use and Easy to Control
Its initial cost is very high.
The process requires over safety precautions which further
enhance the initial cost of the setup.
Some of the workpiece materials are very much prone to
metallurgical changes on excessive heating so this fact imposes
limitations to this process.
It is uneconomical for bigger cavities to be machined.
Advantage
Disadvantage
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The chief application of this process is profile cutting as
controlling movement of spray focus point is easy in case of
PAM process. This is also recommended for smaller machining
of difficult to machining materials.
Application
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Plasma arc machining

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