Regarding the substantial expenses related to the usage of plasma consumables in the upkeep of your CNC plasma cutting machine, we understand your concern. As you know, this particular type of machinery requires a significant initial investment. Regardless of whether you opt for renowned brands like United States Hypertherm, Thermal Mart, or Germany’s Kjellberg ion cutting machines, each offers commendable cutting quality; however, the importance of maintaining these consumables must not be overlooked. Therefore, adopting suitable strategies to curtail waste is crucial – a smart way to economize! By paying heed to the points outlined below, you can significantly enhance both the lifespan and maintenance costs of your gantry CNC plasma cutting machine. Here are some practical tips to help you minimize the cost of using plasma consumables:
Adopt the reasonable cutting height
In accordance with the guidelines provided by the user manual, ensure that you adopt a suitable cutting height. Cutting height refers to the distance between the cutting nozzle and the workpiece surface. During the piercing process, try to use a perforation height slightly higher than that specified in the parameter table.
Ensure the correct air pressure and flow rate of plasma
The ideal plasma air pressure and flow rate plays a vital role in extending the lifespan of consumables. If the air pressure is too high, it will greatly reduce the life of the electrode; conversely, if the air pressure is too low, it may affect the longevity of the nozzle.
Do not overload the nozzle
Exceeding the operating current of the nozzle can lead to rapid nozzle failure. The current intensity should ideally be 95% of the nozzle’s operating current. For example, a 100A nozzle should operate at a current intensity of 95A.
The thickness of the perforation should be within the allowable range of the machine system
The cutting machine is unable to perforate steel plates beyond its working thickness. Typically, the perforation thickness is half the normal cutting thickness (for less than 100A), e.g., a 100A system is configured to cut 1 inch (approximately 25mm) of carbon steel, and the system should have a perforation thickness of 0.5 inches (approximately 12.5mm).
Keep the plasma gas dry and clean
Dry and clean plasma gas is essential for the proper functioning of the plasma system. Dirty gas is often a challenge for gas compression systems, potentially shortening the lifespan of consumables and causing irregular damage. To determine the quality of the gas, set the torch in test mode, position a mirror under it, and consume the gas in the torch. If water vapor and fog appear in the mirror, investigate and rectify the problem quickly.
start cutting from the edges
Whenever feasible, start cutting from the edge rather than piercing through existing holes. Using the edge as the starting point will extend the lifespan of the consumable component. The correct method involves aiming the nozzle directly at the edge of the workpiece before initiating the plasma arc.
Reduce unnecessary arc starting (or arc guiding) time
The nozzle and electrode tend to wear out quickly during the arcing phase. Before starting, position the cutting torch within easy reach of the cutting metal.
Avoid elongation and expansion of plasma arc
If the plasma arc must stretch and expand to make contact with the workpiece surface, it will generate such stretching and expansion at the beginning and end of the cutting process, resulting in abnormal nozzle damage. This problem can be avoided by using the correct edge start technique and selecting the appropriate “arc break” signal duration.
Apply splash-proof chemical paint to the protective case
Anti-splash chemical coatings help minimize the accumulation of slag on the protective shell. However, remember to remove the protective shell from the cutting torch before applying the anti-splash paint.
Clear the gas after replacing consumable parts
After replacing consumable parts or a long shutdown, the gas should be purged (2-3 minutes is appropriate) to retain water and mist from the machine.
Regularly remove debris adhering to the torch’s protective shield
As a best practice, debris accumulated on your torch’s protective shield should be periodically eliminated. Failure to do so may lead to a potentially harmful occurrence of an intense plasma arc.
Effortlessly maintain the cleanliness of your cutting torch and its accessories.
Presence of dust or debris on your cutting torch and its accessories could significantly impair plasma system functionality. When replacing these accessories, kindly lay them on a pristine flannel cloth, routinely inspect the connection threads of the cutting torch, and clean the electrode contact surface and nozzle with a hydrogen peroxide cleaner.
Thoroughly clean the oxide deposits from the air or oxygen nozzles
During usage of air or oxygen plasma, oxides tend to accumulate within the nozzle, which can disrupt the airflow and diminish the lifespan of the accessory components. Please wipe the interior of the nozzle with a fresh lint cloth to eliminate these oxides.
Employ soft water for injection into the cutting torch
Hard water can induce metallic impurities to adhere to the nozzle ring, thus affecting airflow, reducing torch performance, and curtailing the service life of accessory components.
Conduct daily air flow and coolant flow inspections
A common reason behind cutting torch damage is inadequate cooling flow. It is essential to regularly check the air flow and air pressure (in the case of air-cooling) or the coolant (for water-cooling) of the cutting torch. In the event of insufficient air flow or leakage being detected, we recommend the immediate shutdown of the machine for troubleshooting purposes.
