Plasma Arc Cutting

PAC is a thermal material removal process

that is primarily used for cutting thick
sections of electrically conductive
materials.

PAC Process
Plasma is composed of free

electrons that have become

disassociated from the main gas
atoms, positive ions and neutral
atoms with a temperature of plasma
that can be high as 33000 degrees,
which causes rapid metal cutting.
The flowing gas is delivered to the
torch at pressures up to 1.4Mpa
resulting in a plasma high velocity.

www.plasma.org

PAC Process
The high gas flow rate facilitate
the removal of molten metal
from the cut zone.

Types of Torches
1.
2.
3.
4.

Air Plasma Torch

Oxygen-Injected Torch
Water Injected Torch
Dual Gas Torch
Air Plasma (Benedict 337)

Water Injected (Benedict 340)

Types of Arcs
1.
2.

Transferred Arc - the generated arc is between the electrode and the workpiece.
Non-Transferred Arc - the generated arc is between the electrode and the
nozzle and heat is carried to the work-piece by the plasma gas.

Benedict 336

Advantages - Disadvantages

Cuts any metal.

5 to 10 times faster than
oxy-fuel.
150 mm thickness ability.
Easy to automate.

Large heat affected zone.

Difficult to produce sharp
corners.
Smoke and noise.
Burr often results.

Applications

Pipe industry preparing

pipe edges for welding.

industries for shape cutting

Cpam.engr.wesc.edu

Other Plasma Uses

Plasma Arc Welding (PAW)- plasma arc is produced and aimed at
the weld area to weld.

Applications- Used for butt and lap joints because of higher energy
concentrations and better arc stability.

Safety Precautions

Machine the heat affected zone

(0.75-5 mm).
Regulate gas pressure (approx. 11.4 MPa).
Maintain constant distance
between torch and work piece.
High labor safety (i.e. goggles,
gloves, etc).
Proper training for operators.
Protection against glare, spatter
and noise from the plasma.

ADAPTIVE CONTROL MACHINING

PRESENTED BY
RACHIN.S.R 02107037

INTRODUCTION
ADAPTIVE CONTROL MACHINING(AC)

ORGINATED OUT OF RESEARCH IN EARLY

1960S SPONSERED BY THE US AIRFORCE.

AC USES MICROPROCESSER BASED CONTROLS

AND IS TYPICALLY INTEGRATED WITH A
EXISTING CNC SYSTEM.

 IN AC MACHINING THERE IS IMPROVEMENT IN

THE PRODUCTION RATE AND REDUCTION IN
MACHINING COSTS.

THIS OCCURS AS A RESULT OF CALCULATING

AND SETTING OF OPTIMAL PARAMETERS
DURING MACHINING.

ADAPTIVE CONTROL
AC POSSESSES ATTRIBUTES OF BOTH FEEDBACK CONTROL AND OPTIMAL CONTROL

FEATURE THAT DISTINGUISHES AC CONTROL

FROM OTHER TWO TYPES IS THAT AN AC
SYSTEM IS DESIGNED TO WORK IN A TIME
VARYING ENVIORNMENT

 AN AC SYSTEM IS DESIGNED TO OPERATE FOR

THE CHANGING ENVIORNMENT BY
MONITORING ITS PERFOMANCE AND
ACCORDINGLY SOME ASPECTS OF ITS
CONTROL MECHANISM TO ACHIEVE OPTIMAL
OR NEAR OPTIMAL PERFOMANCE

AN AC EVALUATES ITS PERFOMANCE WITHIN

THE ENVIORNMENT AND MAKES NECESSARY

CHANGES IN ITS CONTROL CHARACTERISTICS
TO IMPROVE OR IF POSSIBLE TO OPTIMIZE ITS
PERFOMANCE

FUNCTIONS OF AC
IDENTIFICATION FUNCTION
DECISION FUNCTION
MODIFICATION FUNCTION

ADAPTIVE CONTROL SYSTEM

AC OF METAL WORKING PROCESS IS A

LOGICAL EXTENSION OF THE NUMERICAL

CONTROL AND COMPUTER CONTROL

IN NC PROCESS THE CUTTING SPEED AND

FEEDS ARE PRESCRIBED BY THE PART
PROGRAMMERS

IN PRACTICE THE AC SYSTEMS OF MACHINE

TOOLS CAN BE CLASSIFIED INTO TWO TYPES

AC WITH OPTIMISATION(ACO).

AC WITH CONSTRAINTS(ACC).

DEFINITION
THE TERM AC DENOTES A CONTROL SYSTEM

THAT MEASURES CERTAIN O/P VARIABLES AND

USES THESE TO CONTROL SPEED AND/OR
FEED

THE TYPICAL MEASURES OF PERFOMANCE IN

MACHINING HAVE BEEN METAL REMOVEL RATE

AND COST PER VOLUME OF METAL REMOVEL

WHERE TO USE AC
ONE OF THE PRINCIPLE REASONS FOR USING
NC IS THAT IT REDUCES THE
NONPRODUCTIVE TIME IN A MACHINING
OPERATION.

AC DETERMIES THE PROPER SPEEDS AND

FEEDS DURING MACHINING AS A FUNCTION

OF VARIABLES IN SUCH FACTORS AS WORK
MATERIAL HARDNESS,WIDTH OR DEPTH OF
CUT,AIR GAPS IN THE PART GEOMETRY AND
SO ON

 THE FOLLOWING CHARACTERISTICS CAN BE

USED TO IDENTIFY SITUATIONS WHERE AC
CAN BE BENEFICIALLY APPLIED

1. IN-PROCESS TIME CONSUMES A SIGNIFICANT

2.
3.
4.

PORTION OF THE MACHINING CYCLE TIME

THERE ARE SIGNIFICANT SOURCES OF
VARIABILITY IN JOB FOR WHICH AC CAN
COMPENSATE
COST OF OPERATING MACHINING TOOL IS
HIGH
THE TYPICAL JOB INVOLVES STEEL & HIGH
STRENGTH ALLOYS

SOURCES OF VARIABILITY
1. VARIABLE GEOMETRY OF CUT
2. VARIABLE WORKPIECE HARDNESS &
VARIABLE MACHINABILITY
3. VARIABLE WORKPIECE RIGIDITY
4. TOOL WEAR
5. AIR GAPS DURING CUTTING

BENEFITS OF AC
INCREASED PRODUCTION RATES
INCREASED TOOL LIFE
GREATER PART PROTECTION

LESS OPERATOR NTERVENTION

EASIER PART PROGRAMMING

CONCLUSION
FOR A MACHINING OPERATION AC IS THE BEST
METHOD FOR CONTROLLING THE PROCESS

IT HAS BEEN ESTABLISHED THAT IT WAS

POSSIBLE TO INCREASE THE METAL REMOVING

RATE BY 35% TO 45% BY USING AC
TECHNIQUES

THANK YOU