Tips to Improve CNC Plasma Quality

Achieving better quality is the ultimate goal of plasma technology. 

For this, you can always ask the customer support team for guidance or replace the parts with Mazak used parts. However, with proper information and some cool tips, you can improve your plasma cutting quality on your own. 

 Keep reading to learn more!

1. Cut in the Right Direction

Make sure that you cut properly. While using standard consumables, the plasma arc spins in the clockwise direction as the torch moves forward to cut. The squarest angles are on the right side, and thus, contour shapes are cut in a clockwise direction. It is opposite with internal features. There, the torch needs to travel anti-clockwise. So, adjust the current direction if needed. 

2. Refer to the Cut Charts

Check out the cut charts in your system manual and select the appropriate cutting process for your application. Select the process depending on your material type, thickness, desired cut quality, precision, and productivity goals. Based on these details, the cut chart would show the appropriate consumables, amperage, cut and pierce height, shield gases, etc. The arc voltage measurement, cutting speed, torch to work distance are other parameters listed in the chart. 

3. Use Good Consumables

See if your consumables are worn or damaged. They are essential for precision, and any damage could affect the quality and system performance. Therefore, do a visual check and replace it when needed. Use branded alternatives like Mitsubishi spare parts, or Mazak used parts. Always lubricate o-rings while replacing consumables. Don’t over lubricate, as it may affect the system performance. 

Also, make sure that you choose right consumables. Double-check the part numbers on your consumables with the numbers in the manual. 

4. Level your Table and Workpiece

Always level your torch to the workpiece before you start squaring. Because if the metal is bent or wrapped, it would be impossible to square the torch with the workpiece. Or, in the worst case, you may have to accept the poor cut quality. 

5. Hold Right Torch to Work Distance

Ensure that your torch is not close or far away from work, or it would cause rounded cut edges. On top of that, if the torch is too close, the metal splatter would cause severe damage to the torch and nozzle. So, refer to the distance in the manual and adjust accordingly. If your parts are old, adjust them manually as the distance may vary. 

6. Cut at the Right Speed

If the cut speed is low, it may result in broader kerf, dross, and warpage on thin materials. Often, the low-speed dross is collected at the bottom of the cut edge and is easy to remove and flake off. In contrast, high-speed dross causes a thinner bead of molten metal to collect at the bottom of the cut. It is harder to remove and requires grinding. However, you can eliminate it by reducing the cut speed to allow arc time to catch up with the arc torch. 

7. Use Clean and Dry Air

If you’re using air plasma, make sure it’s clean and dry. The same applies to oxygen or multi-gas systems. Use pure and high-quality gases. Make sure that the regulators and gas lines are of appropriate size. Purge-it manually if required. Also, confirm that the purging cycle is completed. Lastly, see if there are any leakages. In case of emergency, contact your gas distributor and get it resolved immediately. 

8. Tune-up your Table

Is the speed of table cutting appropriate? Is the torch secured tightly to the gantry? Is the table vibrating? 

Check all these as often the plasma cutting problem is not with plasma cutters but the poor motion or table issues. So, tune up your table before proceeding with the cut. 

Most importantly, keep implementing these tips. Share your experience with us. If you have any problem with your system or consumables, contact your manufacturer or supplier immediately.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/tips-to-improve-cnc-plasma-quality

How Laser Cutting Benefits your Business

To get a cut above average, you must first know its detailing. Whether the laser cutting machine is suitable for your product or not. Only when you know the right time to use the latest technology and equipment can improve your product/service quality.

For that, you need to learn about different laser cutting machines, which brand spare parts you should use (like Mazak used parts or Fanuc parts), and so on. 

The most important thing you need to identify is the advantage this technology provides.

Let's see what they are:

1. Versatility

What's the first thing you notice about cutting tools?

It's usually how you can use them from an economy, mass production,, and components perspective. 

Talking about laser cutting, it's highly versatile. Not more people appreciate it, but it's a fact. It's a cost-effective solution for projects that require precision and intricacy.

It's a go-to solution for all metal cutting work.  

Be it aluminum, stainless steel, or titanium, laser cutting can perfectly finish different sizes. You can also apply them to cut zinc and iron.

No matter how hard the material is, it can provide high-quality results. 

2. Reliability

Manual tools and cutting methods rely on well-maintained equipment. They use the sharp cutting blade, but the blade can become blunt, slow, or smooth as the process continues. This may affect the result. There might be variance in edges, or the cutting may not be exact. 

The variances can be minute, naked to the human eye. However, they can make a significant change, mainly if the components are for robotics or automation lines. 

Laser cutting ensures 100% consistency. It ensures that there won't be a difference or distortion of even 0.1mm. 

You can rely on it because it doesn't rely on sharpened blades or oiled mechanisms. Also, there are no maintenance issues. You can directly replace the parts with branded ones, like Fanuc parts.

3. Accuracy

It's another advantage of using laser cutting technology. 

Manual tools rely on varying degrees based on the dexterity of the operator. Even a skilled one would make marginal errors such as a hairline scratch. 

Laser cutting uses digital technology. It's not prone to variations; instead, it offers a high degree of accuracy. 

For example, you want to cut material to create grooves without passing the blade all through the material. The ratio between engraving and the material edge could be fine. For manual tools, it might not be easy. But laser cutting can make that cut with attuned dimensions. 

With laser cutting technology, you can cut minus plus 0.1mm, accurately.

4. Waste and Time Management

Unlike other cutting methods and tools, laser cutting offers a safe environment and reduced waste management.

The goal of this technology is to get results with minimum waste. It means you can get your components or products ready with fewer errors. It also means that you can get more done in less time. As there's no waste, the time spent on clearing the surface is reduced. Next, you can acquire the results in one or two go. 

It's not like the manual tools. You need to move your item to different machines and position them in different angles and directions to get desired results. 

Laser cutting streamlines the process and makes it smooth. Besides, reduced waste management can further help you save costs.

5. Speed

And the primary advantage is it's fast. 

Not only for mass production. If you want to cut a bespoke item, you can take the laser cutting machine, program it, and within minutes, you can operate.

Even if you have a large consignment, you can get it done on time. Laser cutting can cut through the time you would otherwise require to set up a project or a machine. 

Time is also not a challenge. You can use laser cutting technology 24*7. 

Also, you can take repeat orders and fulfill them without re-setting up or adjusting the parameters.

That's how laser cutting technology is.

There are a lot of advantages to it. If you don't go for it today, you may regret it later.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-laser-cutting-benefits-your-business

Modernize Your Old Press Brake Considering These Steps

Having an old press brake machine is like a headache for owners. You go into the dilemma of whether to keep it or sell it. However, replacing the old machine can be a costly deal and logistics can be an added challenge.

But how about retrofitting your existing press brake with parts like LVD press brake or Mazak used parts with increased efficiency? This will help reduce setup time, scrap and even your operator or you will not be skeptical about learning a new press brake machine.

Here are five steps to transform your old machines and make them brand new.

1. Evaluate the Machine’s Condition:

Before performing anything to your machines, you need to study the current condition and know the ins and outs of it.

Make sure you are considering the following things before making any changes.

• Accuracy:

Check the current bending accuracy of your sheets. This depends on the bending method you are using. Are you using coining, bottom bending or air bending for sheet metal?

While checking the accuracy, if you find out that your sheet is bending accurately maintaining all the standards, then there is no need to replace your machines.

In such scenarios, some changes here and there will make all the difference.

• Pedestal Control:

Having proper pedestal control is important. For many Original Equipment Manufacturers (OEMs), having proper pedestal control is important because without these having programmable logic boards are difficult.

Researching the availability of these components can be a perfect solution rather than investing in a new pedestal control.

• Press Brake Control:

Having control over the press brake machine is important. There are various ways to control the press brake. You can either control it manually or with a programmable control head.

In such scenarios, it is important to understand that retrofitting your machine can be difficult and may turn out to be an expensive solution.

But, if the machine is running properly without the need for any digital control then a basic change in it will work for you.

2. Know your machine:

There are various types of press brake machines, parts like LVD press brake, Mazak used parts available in the market. Each of them has different functionalities and features. In such scenarios, you need to understand your machine thoroughly.

3. Understand the pain points:

As the press brake owner or the operator, you need to understand the obstacles you come across while using it. For example, if you frequently move the tool, then you will need to keep adjusting the height of your gauging surface.

In such cases, you need to understand what can be a better option when it comes to working with its tools.

• Depth/ Angles:

Are you manually adjusting the ram depth or angle often? If so, you can increase the productivity by adding the ram axis or Y axis to the back gauge or front gauge.

4. Proper Approach:

If you opt for retrofitting your press brake machine, then, then there are companies doing the same work. They may ask you the overall length of the press brake machine, the distance between the side frame, usage, type of sheet metal are you bending, etc.

They would also ask if is it a single or multiple operated supporting sheets, the control capabilities, and many such things.

Many companies have different controls for different applications. You can use them for things like go-to-positions-style control, make one-off parts or PC based control like networking, offline programming or unlimited storage.

It says that sophisticated control offers great benefits, but in reality, they require more front-end planning. Because these companies require accurate measurements of your tooling.

Wrapping it up:

Having a press brake and maintaining should not be a headache. Before taking any major steps, it is better to rethink, reuse for increased efficiency.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/2020/03/17/Modernize-Your-Old-Press-Brake-Considering-These-Steps