However, as with any piece of equipment you need to know how and why it does what it does and the necessary precautions to do the job safely. Power supply type dc voltage 30v current 40000a current density 500 acm 2 2. The arc is stable and reaches temperatures as high as 33,000c. Plasma arc machiningbasic terms and working learn and grow. The main advantages of laser beam machining are ease of automation for complex cutting patterns, absence of tool wear and. Electrochemical machining ecm is a nontraditional machining process uses the principle of faraday to remove metal from the workpiece. Plasma arc cutting is characterised by fast cutting speeds and is mainly used in mechanised systems. Plasmaarc machining pam employs a highvelocity jet of hightemperature gas to melt and displace material in its path. A new composition of response surface methodology and grey relational analysis coupled with principal component analysis has been proposed to evaluate and. Introduction the plasma arc machining process was introduced to the industries in 1964 as a method of bringing better control to the arc welding process in lower current ranges. Plasma arc cutting as for other arc processes plus there is a danger of severe electric shock from. These methods form a group of processes which removes excess material by various. All cnc machining begins with a part program, which is a sequential instructions or coded commands that direct the specific machine functions. With the high temperature involved, can be used for any material those resistant to oxy.
This process works on the principle of of faradays laws of. Introduction plasma arc machining pam employs a highvelocity jet of hightemperature gas to melt and displace material in its path. Download link is provided and students can download the anna university me6004 unconventional machining processes ump syllabus question bank lecture notes syllabus part a 2 marks with answers part b 16 marks question bank with answer, all the materials are listed below for the students to make use of it and score good maximum marks with our study. Electron beam machiningbasic terms and working duration. Tech cadcam 2,3assistant professor 1,2department of mechanical engineering 3department of mechatronics engineering 1,2,3u v patel college of engineering, ganpat university, mehsana, gujarat, india. In the present investigation, plasma arc cutting of stainless steel 316l materials has been carried out using plasma arc cutting machine.
Unconventional machining processes introduction and. The finish side of the plasma cut is the right side of the cut when facing the direction of travel. Lecture notes on modern manufacturing process dr pramod. Abrasive jet machining has high degree of flexibility, and hence it is typically used for. Plasma arc cutting process and equipment considerations. The term plasma, as employed in physics, means ionized particles. Other machining operations shaping and planing a singlepoint tool moves linearly relative to the work part shaping a tool moves planing a workpart moves broaching performed by a multipletooth cutting tool by moving linearly relative to the work in the direction of the tool axis. Like a router, the direction of travel the plasma torch takes will affect the cut quality. Electron beam machining ebm introduction electron beam machining is a thermal process used for metal removal during the machining process. Plasmaarc machining pam employs a highvelocity jet of high temperature gas to melt and displace material in its path. Other machining operations shaping and planing a singlepoint tool moves linearly relative to the work part shaping a tool moves planing a workpart moves broaching performed by a multipletooth cutting tool by moving linearly relative to.
Following are the advantages of plasma arc cutting. Plasma arc machining pam employs a highvelocity jet of high temperature gas to melt and displace material in its path. The process parameters tested were plate thickness, cutting. Mar 31, 2017 it is a nontraditional machining process in which no physical tool is used. Early plasma cutters were large, slow, and expensive. On the multi parameter optimization of cnc plasmaarc. Fundamentals of arc welding processes, physics of arc, arc forces, arc blow, selection of power sources for different arc welding processes, principles of weld joint design, welding symbols, metallurgical aspects in welding of steel, heat flow in welding and its effect on the performance of weld. Material is removed from the work piece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid. This paper investigates the effects and parametric optimization of process parameters for plasma arc cutting pac of en31 steel using grey relation analysis.
Apr 21, 2015 introduction the plasma arc machining process was introduced to the industries in 1964 as a method of bringing better control to the arc welding process in lower current ranges. The objective of this work is to study the effects of plasma arc cutting process parameters on hazheat affected zone and bevel angle for low carbon steel 1010 material with thickness 4 mm, which. Cnc as it is now known, allows part machining programs to be edited and stored in the computer memory as well as permitting diagnostics and quality control functions during the actual machining. Plasma arc welding is a liquid state welding process in which the metal to metal joint forms in a molten state. Laser beam machining an overview sciencedirect topics. Electron beam machining ebm diagram, working, advantages. This arc is usually on at all times and exists between the tungsten electrode and anode. The electrode and workpiece are immersed in a dielectric liquid, and a feed mechanism maintains a. Edm involves the direction of highfrequency electrical spark discharges from a graphite or soft metal tool, which serves as an electrode, to disintegrate electrically conductive materials such as hardened steel or carbide.
Michael faraday discovered that if the two electrodes are placed in a bath containing a conductive liquid and dc potential 525v is applied across. Introduction the plasma arc machining process was introduced. Plasma arc machining pam kcg college of technology. Tig, plasma arc, mig 36 pages, 47 figures basic level. Oxyfuel gas cutting is mostly limited to only ferrous metal especially plain carbon steels. The torch produces a highvelocity jet of hightemperature ionized gas plasma that cuts by melting and displacing material from the workpiece.
Pilot arc power supply provides power for the nontransferred pilot arc which enables easier ignition of the main welding arc. Nov 19, 2016 introduction plasma arc machining is a material removal process. The cutting is accompanied by a high noise level which can be reduced by operating the torch under water. This process works on the principle of of faradays laws of electrolysis. Nonconductive materials such as wood or plastic cannot be cut with plasma cutters with transferred arc.
May 12, 2017 electrochemical machining ecm is a machining process in which electrochemical process is used to remove materials from the workpiece. The plasma arc process has always been seen as an alternative to the oxyfuel process. Plasma arc machiningbasic terms and working duration. The electrode and workpiece are immersed in a dielectric liquid, and a feed mechanism maintains a spark. A study of effect of various process parameters on. This course on advanced machining processes is also known as. Laser beam machining is a thermal energybased advanced machining process in which material is removed by focusing the laser beam on the work surface at a constant distance to melt and vaporize the unwanted work material. Pam lecture 17 electron beam machining ebm edit lesson lecture 18 laser beam machining lbm lecture 19 chemical machining chm.
In unconventional machining, a form of energy is used to remove unwanted material from. Pam is a method of cutting metal with a plasmaarc, or tungsten inertgasarc, torch. The material removal takes place by directing a high velocity jet of high temperature 11,00030,000. The torch produces a highvelocity jet of hightemperature ionized gas called plasma that cuts by melting and. Optimization of process parameters in plasma arc cutting. Introduction plasmaarc machining pam employs a highvelocity jet of hightemperature gas to melt and displace material in its path. An optimisation of the cutting parameters during cnc plasmaarc cutting of st37 mild steel plates is attempted using robust design. At higher cutting speeds, the plasma jet does not cut through metal plate. Cut direction must be considered when programming the plasma cutter. Electron beam machining ebm and laser beam machining lbm are.
Advantages and disadvantages of plasma arc welding,cutting. Sep, 2016 plasma arc machiningbasic terms and working duration. Plasma arc machining pam plasma arc machining is a nontraditional thermal process. The optimum parameter level for surface roughness are 6. Plasma arc machining machine tool technology britannica. To learn about various unconventional machining processes, the various process parameters. Electron beam machining is same as laser beam machining process in which except laser, high speed electron beam impinges on work piece. In unconventional machining, a form of energy is used to remove unwanted material from a given workpiece. Parametric analysis of cutting parameters for laser beam. In this part of the series the process fundamentals are described with emphasis being placed on the operating features and the advantages of the many process variants. An unconventional machining process or nontraditional machining process is a special type of machining process in which there is no direct contact between the tool and the workpiece. Called pam, this is a method of cutting metal with a plasma arc, or tungsten inertgas arc, torch. A parameter design of cnc plasmaarc cutting of carbon steel.
A parameter design of cnc plasmaarc cutting of carbon. Electrochemical machining ecm is a machining process in which electrochemical process is used to remove materials from the workpiece. Pressure, 150 a current, 400 mmmin cutting speed and 2 mm arc gap. This will generate high heat energy and melts and vaporize metal from work piece. Plasma is defined as a gas that has been heated to a sufficiently high temperature to become partially ionized and therefore electrically conductive. In the electrical beam machining, electrical energy is used to generate the electrons with high energy. Plasma arc machining is one of the most important non conventional machining method used in fabrication industries because of its high accuracy, ability to machine any hard material, ability to produce any intricate shape and better finish.
The plasma arc cutting process is illustrated in fig. Plasma arc machining basic terms and working duration. Laser beam machining lbm is an excellent material processing technique to machine a wide range of advanced materials, especially difficulttomachine advanced ceramics and composites. An optimisation of the cutting parameters during cnc plasma arc cutting of st37 mild steel plates is attempted using robust design. Advanced machining processes video course mechanical.
A study of effect of various process parameters on abrasive. Following are the disadvantages of plasma arc cutting. To learn about various unconventional machining processes, the various process parameters and their influence on performance and their applications. Abrasive jet machining has high degree of flexibility, and hence it is typically used for machining of glass and ceramic materials. The cutting is faster about 5 to 10 times than oxyfuel. Chapter 1 early plasma cutting the plasmaarc cutting process saw its first commercial application in the early 1960s. Various type of plasma arc cutting in this process gases are heated and charged to plasma state. Machine tool electricaldischarge machining edm britannica. A plasma is an ionized very hot gas composed of nearly the same numbers of electrons and ions. Describe the plasma arc cutting process and its applications in the pipefitting trade identify the different components of plasma arc cutting equipment and ppe required for its use. Plasma arc machining is a nontraditional thermal process.
The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. Analysis of process parameters of plasma arc cutting of. Principle, applications, and process parameters and modelling 8. Since no heat is applied on the materials, cut edges are clean. Machine tool machine tool electricaldischarge machining edm.
Its high accuracy, finishing, ability of machining any hard materials and to produce intricate shape increases its. Shielding nozzle directs shielding gas to the weld. Called pam, this is a method of cutting metal with a plasmaarc, or tungsten inertgasarc, torch. In the process, workpiece is taken as anode and tool is taken as cathode. Introduction plasma arc machining is a material removal process. Water jet machining water jet cutting can reduce the costs and speed up the processes by eliminating or reducing expensive secondary machining process. Plasma arc machining basic terms and working learn and grow. In the electron beam machining process, a high velocity focused beam of electrons are used to remove the. The metal shieldedgas welding is limited to the metal inertgas welding process. Laser beam machining lbm plasma arc machining pam electron beam machining ebm 7. Other articles where plasma arc machining is discussed. This is because the holes in the swirl ring produce a swirl in the plasma jet. Optimization of process parameters in plasma arc cutting of. The standoff, or torchtowork distance, is less sensitive with plasma but the torch angle when welding parts of unequal thicknesses is more important than with gas tungsten arc.
Mechanical machining ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. Jun 10, 2017 electro chemical machining consists of following basic elements. In addition, the influence of nozzle length, arc current, and mass flow rate on plasma cutting arc was investigated in research work 4. Anode constricts welding arc and plasma gas through the orifice, delivers powder to the welding arc, maintains the pilot arc. Its high accuracy, finishing, ability of machining any hard materials and to produce intricate shape increases its demand in market. Abrasive jet machining ajm, electrical discharge machining edm, electrochemical machining ecm, laser beam machining lbm and plasma arc machining pam. Plasma arc machining process, diagram, advantages and.
The two electrodes workpiece and tool is immersed in an electrolyte such as nacl. Further, the concept of hot wire tig welding process has also been elaborated. An optimization concept of the various machining parameters for the plasma arc cutting procedures on aisi 316 stainless steel conducting a hybrid optimization method has been carried out. At lower speeds, the molten metal from the kerf sticks to the bottom of the plate. May 12, 2017 plasma arc machiningbasic terms and working learn and grow. Lbm can be used to process these materials with intricate shapes and sizes with greater precision even difficult to reach surfaces. For example, for 12 mm steel, plasma cutting costs are about half those of oxyfuel. Mar 24, 2020 this is an arc welding process, a concentrated plasma arc is produced and directed towards the weld area. Principles equipment types beam control techniques. The electrolyte in ecm should have high electrical conductivity, low viscosity, high specific heat, chemical stability, resistance to form a passivating film on the workpiece surface, non. Narrow plasma jet melts the workpiece material in its path.
The objective of this work is to study the effects of plasma arc cutting process parameters on hazheat affected zone and bevel angle for low carbon steel 1010 material with. In thesis work literature has been studied in context to parametric optimization of plasma arc cutting machine. Consequently, common applications for pac consisted of repeating cutting patterns in a massproduction mode. In electro chemical machining an electrolyte acts as a current carrier.
Plasma arc machiningbasic terms and working youtube. Pdf experimental investigation of the plasma arc cutting. In lbm, there are many factors such as beam parameters, material parameters and machining parameters which affects the various quality characteristics, e. Main arc power supply provides power for the transferred welding arc between the tungsten electrode and base metal. The plasma welding process does respond differently to these variables than does the gas tungsten arc process. Disadvantages of plasma arc machining the cutters electrode and nozzle sometimes require frequent replacement which adds to the cost of operation. Plasma arc machining plasma is defined as the gas, which has been heated to a sufficiently high temperature to become ionized. Paw plasma arc welding pjpw plasma jet plasma arc welding gmgmma gasmixture. Electrolysis is based on faraday laws of electrolysis which is stated as. The plasma welding consists only of the plasma arc welding process which works with a transferred arc. Plasma state is the superheated and electrically ionized gases at approximately 5000c these gases are directed. Electrochemical grinding ecg, electrostream drilling esd, shaped tube electrolytic machining stem chemical.