Non-Conventional Machining Series

Plasma Arc Machining Manual

Department of Industrial &

Manufacturing Engineering,

University of Engineering &

Technology, Lahore.
 LAB SESSION: 11
PLASMA ARC MACHINING

Problem Statement

Plasma cutting is a process that is used to cut steel and other metals of different thicknesses
(or sometimes other materials) using a plasma torch. It is required to study different
parameters involved and investigate the cause of different defects produce when several
parameters overlap intricately.

Objective

To understand the working principle and basic operating parameters of Plasma Arc Machining.

Theory

What is Plasma?
To properly explain how a plasma cutter works, we must begin by answering the basic
question “What is plasma? In its simplest terms, plasma is the fourth state of matter. We
commonly think of matter having three states: a solid, a liquid, and a gas. Matter changes
from one state to the other through the introduction of energy, such as heat. For example,
water will change from a solid (ice) to its liquid state when a certain amount of heat is
applied. If the heat levels are increased, it will change again from a liquid to a gas (steam).
Now, if the heat levels increase again, the gases that make up the steam will become ionized
and electrically conductive, becoming plasma. A plasma cutter will use this electrically
conductive gas to transfer energy from a power supply to any conductive material, resulting
in a cleaner, faster cutting process than with oxy-fuel.

The plasma arc formation begins when a gas such as oxygen, nitrogen, argon, or even shop
air is forced through a small nozzle orifice inside the torch. An electric arc generated from
external power supply is then introduced to this high pressured gas flow, resulting in what is
commonly referred to as a “plasma jet”. The plasma jet immediately reaches temperatures up
to 40,000° F, quickly piercing through the work piece and blowing away the molten material.
Principle
When a free-flowing gas is heated to a very high temperature it becomes partially ionized.
This ionized gas is called as plasma. In this process metal is removed from the surface of the
work piece with the help of high temperature plasma. Metal is also moved because of
electron bombardment.
 Figure 1: Working Mechanism of Plasma Arc Machining

Plasma Cutting
Plasma cutting is a process that cuts through electrically conductive materials by means of an
accelerated jet of hot plasma. Typical materials cut with a plasma torch include steel,
aluminum, brass and copper, although other conductive metals may be cut as well. The
temperatures generated are very high (9400°C in the torch for oxygen as a plasma gas).
Consequently, the process is fast, the kerf width is small, and the surface finish is good.
Plasma Machining is often used in fabrication shops, automotive industrial construction
& salvage and scrapping operations. Due to the high speed and precision cuts combined with
low cost, plasma Machining sees widespread use from large-scale industrial CNC
applications down to small hobbyist shops.

Plasma System Components

 Power supply: The plasma power supply converts single or three phase AC line
voltage into a smooth, constant DC voltage ranging from 200 to 400VDC. This DC
voltage is responsible for maintaining the plasma arc throughout the cut.

 Arc Starting Console: The ASC circuit produces an AC voltage of approximately

5,000 VAC at 2 MHz which produces the spark inside of the plasma torch to create
the plasma arc.

 Plasma torch: The function of the plasma torch is to provide proper alignment and
cooling of the consumables. The main consumable parts required for plasma arc
generation are the electrode, swirl ring, and nozzle. An additional shielding cap may
be used to further improve cut quality, and all the parts are held together by inner and
outer retaining caps.
Plasma Handheld Controller
The handheld controller is used to control the machine. The controller has different color
keys with different functions.

Figure 2: Plasma Handheld Controller

Note: Discuss the handheld controller in detail explaining the functions of all keys.

Process Parameters
Plasma cutting is a process that is used to cut steel and other metals (or sometimes
other materials) using a plasma torch. In this process, an inert gas (in some units,
compressed air) is blown at high speed out of a nozzle, at the same time an electrical
arc is formed through that gas from the nozzle to the surface being cut, 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. Plasma can also be
used for plasma arc welding and other applications
Safety Precautions

Ensuring the plasma cutter is grounded and wired properly

 Wearing rubber gloves in addition to welding gloves

 Standing on a rubber mat whilst cutting
 Ensuring the working environment – including the person – is not wet or have
moisture

Safety around ground cables

Faulty wiring in any electrical device can be dangerous, particularly for plasma cutters.
Always check the functionality of the ground cable and if there are complications, repair it
with the help of an expert.

Eye protection for arc rays

Plasma cutter arc rays produce severe infrared and ultraviolet rays, which are harmful for
both the eyes and skin. Before you begin, ensure your clothing protects your skin and wear a
face shield or safety glasses fitted with the correct safety lenses.

Protective clothing

As you will be exposing yourself to high molten metal and fumes, its imperative you shield
yourself with personal protective gear. These are just some of the clothes that should be worn
when welding metals:

 Protective shield or hat that covers the head fully

 Safety shoes, ideally leather top steel toe shoes or boots
 Welding gloves
 Protective eye gear
 Non-flammable welding aprons and clothing

Precautions to lessen toxic gasses and fumes

As the plasma cutting process produces fumes and gasses, it’s highly advisable that welders
work in a well-ventilated environment.

Our highly skilled profile cutting team possess years of specialized training and follow the
most up-to-date safety processes when using plasma cutters, laser and oxy cutting tools
on steel plates.

Applications
The process of plasma arc welding is quite popular with the commercial welders. In fact, as
every good commercial welder knows, the plasma arc welding has a wide range of
applications. The process of plasma arc welding can slowly start an arc to some small
components and to the tip of wires and proceed with making welds that are repeatable and
come with short periods of welding. Commercial welders confirm that this is quite to the
advantage when the welding components are wires, needles, probes, thermocouples, light
bulb filaments, as well as surgical instruments.
 
When the commercial welder has to work with electronic components or with various
medical instruments that are hermetically sealed or are sealed through welding, then the
plasma process gives them the chance to weld close to the delicate seals, to reduce the heat
input and to start the arc without the high frequency electrical noise as it could damage the
internal parts of the electrical device.
 
In general, the repair and the welding industry try to assist the companies that want to reuse
the components that have sight dents from wear or misuse. The commercial welders today
can start an arc with low amperage and can make the necessary repairs. This option offers the
users an alternative to the typically used heat treatment and conventional repair. The
micro plasma welding process and the micro TIC welding process are used in tool and mold
repairs. If there are outside edges then the plasma arc process offers stability of the arc and
control over the weld puddle. When there are inside corners, the TIG process allows for
extension of the tungsten welding electrode, which improves the process.
What are the advantages of Plasma Arc Machining?
Advantages of PAM are given below:
(a) it gives faster production rate.
(b) Very hard and brittle metals can be machined.
(c) Small cavities can be machined with good dimensional accuracy.
What are the limitations of Plasma Arc Machining?
A major limitation in implementing a plasma welding process is the relatively high
startup costs. Plasma welding equipment tends to be expensive. Because it is a more
specialized welding process, the training and expertise required is also more intense.