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    1) Plasma arc machining (PAM) uses a high-temperature plasma stream to cut metal by melting and blowing away the molten material. 2) Key factors that influence the PAM process include parameters of the plasma torch, the physical setup configuration, and the environment of the cutting. 3) PAM provides benefits such as high cutting speeds and the ability to cut metals that are difficult to cut through other methods, but limitations include high equipment costs and heat-affected zones in the cut material.

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    Amp Report

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    1) Plasma arc machining (PAM) uses a high-temperature plasma stream to cut metal by melting and blowing away the molten material. 2) Key factors that influence the PAM process include parameters of the plasma torch, the physical setup configuration, and the environment of the cutting. 3) PAM provides benefits such as high cutting speeds and the ability to cut metals that are difficult to cut through other methods, but limitations include high equipment costs and heat-affected zones in the cut material.

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    1) Plasma arc machining (PAM) uses a high-temperature plasma stream to cut metal by melting and blowing away the molten material. 2) Key factors that influence the PAM process include parameters of the plasma torch, the physical setup configuration, and the environment of the cutting. 3) PAM provides benefits such as high cutting speeds and the ability to cut metals that are difficult to cut through other methods, but limitations include high equipment costs and heat-affected zones in the cut material.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    41 views21 pages

    Amp Report

    Uploaded by

    Aadip Kushwaha
    1) Plasma arc machining (PAM) uses a high-temperature plasma stream to cut metal by melting and blowing away the molten material. 2) Key factors that influence the PAM process include parameters of the plasma torch, the physical setup configuration, and the environment of the cutting. 3) PAM provides benefits such as high cutting speeds and the ability to cut metals that are difficult to cut through other methods, but limitations include high equipment costs and heat-affected zones in the cut material.

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    of 21

    Plasma Arc Machining

    (PAM)

    Jaypee University of Engineering and Technology


    Department Of Mechanical Engineering

    Priyam dwivedi (161E029)


    Vivek chhabra (161E051)
    Vivek singh (161E052)
    Suryansh singh (161E053)
    Sanchay shrivastava(161E054)
    Synopsis
    • Introduction

    • Principle

    • Mechanism of material removal

    • Process - types

    • Process parameters

    • Advantages

    • Limitations

    • Applications
    Introduction
    • A plasma is defined as a superheated, electrically ionized gas
    • PAC uses a plasma stream operating at temperatures in the range from
    10,000 to 14,000 ºC to cut metal by melting.
    • The cutting action takes place by directing the high- velocity plasma
    stream at the work, thus melting it and blowing the molten metal through
    the kerf
    • Plasma is encountered in electrical discharges, such as fluorescent tubes
    and electric arcs, lightning, high temperature combustion flames and
    the sun.
    • Most application of PAC involve cutting of flat metal sheets and plates.
    Operations include hole piercing and cutting along a defined path.
    • PAC was initially employed to cut metals that are difficult to machine by
    conventional methods. However, in recent years, PAC has also been used
    to cut plain carbon steel, stainless steel and aluminium
    Principle
    • When heated to elevated temperatures, gases turn into a distinctly different
    type of matter, which is plasma
    • When gases are heated by an applied electric field, an igniter supplies the
    initial electrons, which accelerate in the field before colliding and ionizing
    the atoms. The free electrons, in turn, get accelerated and cause further
    ionization and heating of the gases. The avalanche continues till a steady
    state is obtained in which the rate of production of the free charges is
    balanced by recombination and loss of the free charges to the walls and
    electrodes.
    • The actual heating of the gas takes place due to the energy liberated when
    free ions and electrons recombine into atoms or when atoms recombine
    into molecules
    Mechanism of Material removal
    • The metal removal in PAM is basically due to the high temperature
    produced.
    • The heating of the work piece is, as a result of anode heating, due to
    direct electron bombardment plus convection heating from the high
    temperature plasma that accompanies the arc.
    • The heat produced is sufficient to raise the work piece temperature above
    its melting point and the high velocity gas stream effectively blows the
    molten metal away.
    Typical plasma torch construction
    Process types

    • Plasma generating torches are of two general designs – transferred


    plasma torch and non-transferred plasma torch.
    Transferred plasma torch
    • In this torch, the cathode is connected directly to the negative of the D.C.
    source, while the anode nozzle is connected to the positive of the supply
    through a suitable resistor to limit the current through the nozzle to about
    50amps.
    • The metal workpiece to be processed is then connected directly to the
    positive of the supply. When ignited, a pilot plasma flame is established
    between the cathode and nozzle, which provides a conducting path for a
    high current constricted arc between the cathode and workpiece. Once
    this arc is struck, the pilot flame circuit is disconnected.
    • This method is limited to cutting, welding and hard surfacing of
    metals.
    • The electro thermal efficiency is about 85-90%
    Non-transferred plasma torch
    • In this torch, the D.C power source is connected directly across the
    cathode and the nozzle, thus ionizing a high velocity gas that is streaming
    towards the workpiece.
    • The anode dissipation is lost in useless heating of the nozzle.
    • The electro thermal efficiency is about 65-75%
    Process parameters
    • Parameters that govern the performance of PAM can be divided into
    three categories:
    1. Those associated with the design and operation of the torch – eletrical
    power delievered , the gases used to form the plasma, the flow rate of
    the gases through the torch, the orifice diameter through the nozzle duct
    2. Those associated with the physical configuration of the
    set up – torch standoff, angle to the work, depth of
    cut, feed into the work and speed of the work toward
    the torch
    3. Environment in which the work is performed – cooling
    that is done on the bar, any protective type of atmosphere used to reduce
    oxidation fo the exposed high temperature machined surface and any
    means that might be utilized to spread out or deflect the arc and plasma
    impingment area
    Advantages
    1. The main advantage of PAM is speed. For example, mild steel of 6mm
    thick can be cut at 3m/min
    2. The plasma arc can be used to cut any metal or even to non-
    conducting materials like concrete etc., since it is primarily a
    melting process
    3. Due to high speed of cutting the deformation of sheet metals is
    reduced while the width of the cut is minimum
    4. Owing to the high productivity of the plasma arc cutting coupled with the
    tendency to use cheap and easily available plasma-forming media (air,
    water, ammonia etc.,), PAC is finding ever increasing application.
    5. Smooth cuts free from contaminants are obtained in the process 6.Profile
    cutting of metals especially of stainless steel and aluminium
    can be very easily done by PAM
    7.Operating costs are less when compared to oxy-fuel torch 8.Can
    be automated
    Limitations
    • The main disadvantage of PAC is the high initial cost of the equipment.
    However, it can be made economical, if the quantity involved is large
    and the thickness is up to 50mm.
    • Well-attached drops on the underside of the cut can be a problem
    and there will be heat- affected zone (HAZ). The depth of HAZ
    depends on the material and its thickness
    • Smoke and noise
    • Sharp corners are difficult to produce because of the wide diameter of
    the plasma stream
    • Burr is often produced
    • Taper on the workpiece may occur
    Applications
    1. Chiefly used to cut stainless steel and aluminium alloys. It is
    preferred to oxy-fuel cutting because it produces comparatively
    smoother cuts and is free from contamination
    2. Other metals which are resistant to oxy-fuel cutting and hence cut by
    PAC are magnesium, titanium, copper, nickel and alloys of copper and
    nickel
    3. PAC can be used for stack cutting, plate beveling, shape cutting and
    piercing.
    4. It can also be used for underwater cutting.
    5. The plasma jets are used for welding materials like titanium,
    stainless steel etc.,
    6. Plasma arc is used for depositing filler metal on surface to obtain
    desired properties like corrosion resistance, wear resistance,
    toughness or anti-friction properties – Plasma arc surfacing
    7. The plasma arc can also be used for spraying a prepared surface of the
    base material with droplets of molten metal to obtain a surface of required
    thickness
    Research paper on Plasma arc cutting

    Abstract

    The plasma cutting process is investigated experimentally in the present paper for
    assessing the quality of the cut. The quality of the cut has been monitored by
    measuring the kerf taper angle (conicity), the edge roughness and the size of the
    heat-affected zone (HAZ). This work aims at evaluating processing parameters,
    such as the cutting power, scanning speed, cutting height and plasma gas pressure.
    A statistical analysis of the results has been performed in order for the effect of each
    parameter on the cutting quality to be determined. The regression analysis has been
    used for the development of empirical models able to describe the effect of the
    process parameters on the quality of the cutting.
    Objective
    The objective of this paper is the investigation and determination of the most
    important parameters that influence the cutting quality on oxygen plasma cutting.
    Oxygen as a cutting gas is of low cost against other cutting gases. For this reason,
    there is a trend in industrial practice to be extensively used for cutting mild steel. On
    the other hand, oxygen is an active gas reducing the cutting quality of the cuts. The
    effect of the most important parameters on quality characteristics, such as cutting
    edge surface roughness, conicity and heat affected zone (HAZ), for cutting of mild
    steel was assessed. Statistical analysis of the results has been utilized for
    determining the contribution of each individual parameter to the cutting quality.
    Experimental Results and Discussion
    The cut quality was assessed in terms of cutting edge surface roughness, conicity
    (edge inclination) and HAZ. The cutting edge surface roughness was measured
    every 20mm along a 150mm length of the centerline in every specimen.
    Allowance was made for non steady state conditions at the beginning and the end
    of the cut. The variation of surface roughness (Ra) was measured with a diamond
    tipped stylus, surface measurement instrument (Mitutoyo SJ-400). An optical
    microscope Leitz was used for the observation and measurement of each
    specimen. The conicity (edge inclination) was calculated based on the kerf
    measurement. For the measurement of the HAZ, a Nital etchant (solution of 4%
    nitric acid in alcohol) was applied on the processed area. The etched surface was
    examined visually with an optical microscope to detect detrimental microstructural
    modifications that result from overheating during plasma cutting machining.
    Fig. 6. Effect of cutting height on the conicity,
    fr om left to right: cut height too high, too low and optimum
    References

     www.sciencedirect.com
     www.wikipedia.com
     www.thomasnet.com
     Experimental Investigation of the Plasma Arc Cutting Process
    K. Salonitisa,*, S. Vatousianosb

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