Plasma Cutting Machine: Function, Advantages, and Disadvantages

There are multiple metal cutters in the market. To cut thick metal sheets, plasma cutters are widely used.

Plasma cutting is a thermal cutting method where ionized gas is used to cut the metals. Plasma is the fourth state of matter found in the upper parts of the earth’s atmosphere. The polar lights are made of solar winds made of plasma. In daily life, we see a lot of electronic appliances like plasma TV, neon signs, fluorescent lamps, etc. To learn more about plasma cutters and to understand how they work, keep reading.

How Plasma Cutters Work?

Plasma cutters use thermal energy i.e. heat to cut the metals. They have compressed gas like nitrogen that is ionized. This ionization of gases creates palma. The compressed gas comes in contact with the electrode and the pressure is created to ionize the gas. Slowly the pressure builds up and the stream of plasma is pushed towards the cutting head. This head constricts the stream and then subjects it towards the workpiece. 

The plasma is conductive and so the workpiece is connected at the ground of the cutting cables. The plasma arc comes in contact with the metal and due to high temperature the metal melts. And at the same time the molten metal is blown away by the air flow.

Consumables

As plasma cutters use heat to cut materials, there are parts in the cutter that require regular replacement. The hand held plasma cutter parts like nozzle, lenses, hypertherm powermax 85 consumables, etc. must be replaced regularly because they can affect the cutting quality if not in proper condition. Also, the quality of the consumables suggest how long they will last. The consumables must be replaced by the trained or certified technician because if they are not fixed properly, they can affect the quality of the cut, destroy the cutting sheet and also the machine in the worst case scenario. You must consider the maintenance charges and cost of replacement parts while setting a budget for the machine. 

Advantages of Plasma Cutting Machine

Here are some reasons you must invest in a plasma cutting machine.

• Plasma cutters can cut almost all conductive materials

• No need to warm up the laser cutter

• They are suitable to cut thick metal sheets up to 50 mm to receive the best cut quality and maximum up to 150 mm

• They are affordable

• They are the best for stainless steel and aluminum

• They have high precision

• Also suitable for inwater cuts which can reduce noise levels as well

• They are fast when compared to oxy fuel

• Can be used for welding

• Less risky

Disadvantages of Plasma Cutting Machine

No machine is perfect. Here are some disadvantages of the cutters which you must know before buying one.

• The heat affected zone (HAZ) is larger compared to other laser machines

• Requirement of hypertherm powermax 85 consumables is high and it can cost you more

• They have better quality with thinner sheets and plates

• They have less tolerances

Conclusion

The plasma cutter machine is best if your business requirement needs you to deal with multiple types of materials. The shelf life of the machine is long if they are maintained properly. The hand held plasma cutter parts require regular maintenance. You must clean them daily to ensure you have beautiful precise cuts every time you use it. The next thing is trying the first cut on a sample piece to avoid ruining the actual sheet. Once all the settings are proper, you can continue with larger orders.

 

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6 Things to Keep in Mind Before and After Purchasing Laser Machine

Businesses are buying laser machines for various purposes like, cutting, engraving the metals, non-metals or wood. One machine cannot work for all kinds of materials. The capacity and type of laser machine plays a major role in the cutting process. The laser machines require a regular cleaning process and maintenance to get the best quality cuts. Some parts also require replacement in order to save the machine from any further damage. You can find dealers and suppliers who sell authentic and good quality trumpf laser parts or trumpf spare parts, amada spare parts. They also have technicians to help you out with the process. Here are some things to keep in mind if you are looking for a Laser machine or if already have one.

Research Well Before Buying the Laser Machine

Purchasing a laser machine is a huge investment for a business. There are a variety of machines in the market with different sizes, power, and function. So before buying, you must know what are your requirements and purpose of using a laser machine. You can have conversations with the suppliers or distributors and have their opinion as well. You can also ensure whether they have stock of good quality spare parts or not. As you will need to replace some parts at regular intervals of time.

Laser Machine Installation

The certified technician is responsible for setting up the machine including air suction, drainage, and other things. They will know the right setup techniques as there are certain parts that depends on the weather in your region. For example, if you have humidity, you might need an air dryer and cleaner around the compressor. Compressors sometimes have oil and water in the air they produce. If the oil or water blows out from the laser head then it will stick on the lens. The room you install the machine in should be dust free.

Water Drainage System

The water exhaled from the compressor will be collected in the tank. It is advisable to regularly empty the tank. You can also install an auto drainage system so that you will never have an overflowed tank. This can be useful especially when you have long working hours. You do not have to keep checking the tank or there is nothing to worry in case you forget to empty it manually.

Maintain Air Pressure

Regulating the air support is mandatory in the laser machine. The air support depends on whether you are cutting or engraving. The air support will be higher when you are engraving on the metal sheet. If the air support is not high enough then the material might catch fire. So to avoid such situations, maintain your air support and turn it higher if required.

Lens Maintenance

Lens are an important part of the laser machines. Any wrong setting or problem with the lens can reduce cutting quality. It can also damage the machine if not placed properly. Initially, the technician will help you fix the lens. The lenses are expensive, so to ensure you do not damage the lens, proper fitting and cleaning are required. You must daily clean the lens with the cleaning tools to ensure there is no dust on the lens. 

The red laser dot must be clearly visible as it works as the starting point. After long use of the lens, it will require replacement. You must buy the lens from the certified dealers or suppliers. You can buy good quality trumpf laser parts, amada laser parts, etc. and replace them with the old ones. They will last longer and provide good quality cuts.

Test Before You Actually Start

Before starting the mass cutting process, you should always test first. It is possible that if settings are not proper, then the cuts may turn out different from what you expected. So, you can always try it on a sample piece and then start with your actual sheet. If all the settings are proper and still the quality of the cut is not what you expected, then maybe it's time to change the worn out spare parts. You can find dealers who sell authentic trumpf spare parts, amada laser parts, etc. and replace the parts with new ones. 

Conclusion

The laser machines make the cutting process much faster. The quality of the cuts is also smooth as laser machines use CNC machines. This computerized machine sends the signals to the machines who then perform the cut. Maintaining the machine and using it the right way will increase the shelf life. To always get the best quality cuts and to save laser machines from any type of damage, above tips can turn out to be helpful.

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4 Tips to Maintain Fiber Laser Cutting Machine

Cleaning and maintaining the machine and the surrounding is important to get the best quality cuts from a laser machine. Maintaining the machine properly also increases the shelf life. It is not necessary to do all the cleaning processes daily. There are some parts that require cleaning after every use, while some can be cleaned after a few days of using it. Here are some tips to help you on what parts require cleaning and how you can do it.

Lens Maintenance

Before starting the fiber laser cutting machine, check whether the mirrors are clean or not. If there is dust on the lens, clean them with the rubbing alcohol and cotton swab. To ensure the beam quality is the best, clean lenses are mandatory. Because they easily get dirty due to dust and smoke from the cutting. So before using the machines cleaning them is necessary. 

If the mirror surface is flat and there is no lens holder, you can use lens paper to clean them. If the mirror is curved and has a lens holder then you use a cotton swab to clean them. Also, long use of the lens, or cleaning lenses with other tools can make scratches on them. You must immediately replace them. You can use good quality spare parts like fanuc parts, amada parts, etc. and replace the spoiled lens.

Cutting Head Maintenance

If you want the perfect cut then having a cutting head at a proper position is extremely important. Before using the machine, check whether the laser is emitting from the center of the nozzle. If this is not the case then calibrate or readjust the cutting head. Also adjust the height to a suitable drilling position. You must always try first on the sample piece to check whether the cutting head is reaching the sheet and if it is then whether the cut is dip enough or not. You can change the parameters if required. Even after setting all parameters correctly, if you do not receive the proper cut then it is time to change the nozzle. You can buy good quality spare parts like fanuc spare parts, amada spare parts, etc. 

Chiller Maintenance

The water chiller is used to keep the laser cutting machine cool. The chiller will ensure that the machine operates at the constant temperature. You have to keep checking the temperature of the water in the chiller at regular intervals, especially when working for long hours. The water in the chiller needs to be replaced regularly. You can clean the chiller once or twice a month by replacing the water with distilled purified water.

Daily Maintenance 

Here are some daily maintenance tips for the laser cutting machine.

1. After you finish using the machine, clean the workbench. Also keep the laser cutting machine clean.
2. Ensure X, Y, and Z-axis are at the origin.
3. Check the fan of the control box is working normally. Also the connecting wire must be tight and after use they must be disconnected.
4. The screws on the X and Y-axis must be cleaned and lubricated every week.
5. Replace any parts that require replacement with good quality fanuc spare parts, amada spare parts, etc.

Conclusion

The maintenance of the machine ensures that the machine and its spare parts remain in the working condition for a long period of time. There are parts that require regular replacement in order to have good quality cuts. You should always buy the spare parts from authentic dealers, so that you have genuine spare parts. You can buy some good quality spare parts like fanuc parts, amada parts, and trumpf parts online.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/4-tips-to-maintain-fiber-laser-cutting-machine

Fiber Vs. CO2 Laser: Pros and Cons

After the invention of computer-controlled machines, CO2 lasers gained a lot of popularity in the market. Later on, fiber lasers came into the market. Both these machines have their own advantages and disadvantages when we compare their speed, cost, precision, and more. And so, the manufacturing industries often feel confused when choosing between Fiber and CO2 laser cutters. To make it easier for you, we have explained both the laser machines and including pros and cons.  

What is a Fiber Laser Cutting Machine?

The CNC machine controls the light source from the resonator and delivers it to the cutting head. The laser is emitted from the end of the cable and refocused to a series of focal lenses on the cutting sheet. The fiber laser has cutting gasses like NO2 and O2 around the material, which helps in vaporizing the intense heat and blowing away the dust particles.

 

Fiber lasers are generally used for etching, engraving, and metal annealing. As they produce small focal diameters (which means higher intensity), it is suitable for the high contrast markings like serial numbers, barcodes, data matrices on the metals, etc. They are often used for product traceability by directly marking the product parts.

 

The fiber machines require less maintenance and have a long service life. Also, using good quality spare parts like Mitsubishi laser consumables or Trumpf laser consumables will increase the shelf life of the parts. The size of the machine is smaller than the CO2 lasers. Also, the electrical efficiency of the fiber laser is high, so it significantly uses less power than CO2 lasers, which means substantial cost savings. 

 

Apart from cutting, fiber lasers are also used for industrial cleaning applications like removing dust, paint, oxides, and any kind of contaminants.

 

What is a CO2 Laser Cutting Machine?

The light from the CO2 resonator is refocused by using a series of lenses for the reflection process. Here the cutting head emitted light. The path of the reflection process is protected with laz gasses to keep the path clean and dust-free. Thus, this beam path delivery system ensures no dust interferes with the delivery, and the laser path passes with full intensity. 

 

The CO2 laser is ideal for a wide range of non-metallic materials like textiles, plastics, glass, acrylic, wood, and stones. It is also used in pharmaceutical and food packing. We can also use it for marking PVC pipes, mobile gadgets, electrical appliances, integrated circuits (IC), and electrical components. The CO2 lasers are best for cutting thicker materials. 

 

For all materials above 5mm, CO2 laser can deliver faster piercing, straight-line cutting, and a smooth finish. The one drawback of the CO2 laser is that it consumes more power when compared with the fiber laser, which means higher cost of operation. Last but not the least, make sure to use good quality Trumpf, Amada, or Mitsubishi replacement parts for better cut quality.

 

Pros and Cons of CO2 and Fiber Laser Cutter

 

Advantages of CO2 Laser

1. The CO2 lasers leave the best edge quality specially for aluminum and stainless workpieces.
2. They can also be used for cutting non-metals.
3. As these technologies have been in use for so many years, the results are predictable, and the user has assurance of the quality of the cuts.

 

Disadvantages CO2 Laser

1. The CO2 laser requires a blower, chiller, and beam path delivery system to ensure the working of the laser beam. All these processes consume a lot of power and, thus, it is costly.
2. You require regular maintenance of the system, which adds up to the cost.
3. It is not the best choice when it comes to cutting thin materials.

 

Advantages of Fiber Laser

1. The fiber laser cutting system is cheaper compared to CO2 lasers.
2. With the use of mirrors, gasses for the beam path delivery system, the cost of maintenance is reduced. And the consumables from good brands like Mitsubishi replacement parts, and Amada replacement parts can be easily found online.
3. The fiber laser is way faster than the CO2 laser.
4. They consume less power compared to CO2 lasers.

 

Disadvantages of Fiber Lasers

1. Fiber lasers do not give a proper finish while cutting thicker materials compared to CO2 lasers.
2. They are compatible with cutting non-metals.
3. They are not as known and familiar to the users as the CO2 lasers.

 

Conclusion

The choice is yours; if your business requires cutting non-metals, then go for CO2 lasers, and if you require a cost-effective and faster machine, you must go for the fiber laser cutter. Both the laser machines are best in their own way, and to keep receiving the best performance from both, it is important to maintain them. For that, you can use good quality Mitsubishi laser consumables, Trumpf laser consumables, etc. Suitable quality consumables will last longer, and you will receive good quality cuts for a more extended period of time.

 

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/fiber-vs-co2-laser-pros-and-cons

Top 5 Tips to Maintain a Fiber Laser Cutting Machine

There is a lot that goes behind the metal fabrication business. The fiber machine requires a proper way of maintenance in order to receive the best cuts. Thus, proper maintenance of the machine will save you from troubles in the future. And if it requires major changes,then you might have to halt the production. This will cause waste of money and time. So here are some maintenance tips for the fiber laser cutter machine.

Regular Cleaning

Cleaning is a basic yet essential process to prolong life of a fiber laser cutting machine. You can divide the cleaning task in three different ways: daily, monthly, and yearly. Let us discuss some of the daily cleaning tasks. It is the job of the operator to clean the device. They should empty the slag bins and drawers after every cut because if they do not then it is possible that the drawer might jam. All the surfaces must be cleaned so that new sheets can be placed on a clear surface.

The next step is examining the torch. The torch is the nucleus of the fiber laser cutter and its malfunctioning can affect the quality of the cut and damage the machine as well. Also, the cleaning torch helps in making the most precise cuts. So, it is important to clean the torch, nozzle, cables, and the surrounding windows. To clean these, the operators must use a microfiber towel or a lint free cloth. After a while, some spare parts like conical nozzle, chrome nozzle, lens, etc. will require a change.

The area around the machine must also be kept clean. This will ensure no one trips over those things and injures themselves. Ensure all the connections are secured and there is no loose wire. These simple verification practices can help you save from future headaches.

Temperature Maintenance

Fiber laser vaporizes metal with heat to cut the material. The operators must try to keep the equipment cool. The coolers must be checked regularly to ensure they are working properly. Its filters, fans, and coolant levels must be cleaned. If the machine overheats, then it can cause issues to the machine and its spare parts. So it is important to keep track of the temperature.

Ensure Gas Leakage

Fiber laser uses machines to operate and vaporize the material. If the gas is contaminated then the quality of the cut depreciates. So for a smooth cut, the gas must be as clean as possible. If the operators observe a leak, they must change the bottle as soon as possible. Because ignoring the situation can cause more damage and affect productivity and also pose risk to the lives present there.

Align the Machine

To get the straight cuts, it is important that the machine is aligned properly. The operators can check the verticality of the machine every few weeks or when they find any uneven cuts. If the cuts are not smooth or if the material is not cut the way through then the operators must adjust the alignment of the machines accordingly.

Miscellaneous Tasks

The operators must ensure that the parts that require lubrication are properly lubricated. If any parts require oil change then it must be changed regularly. Also, the belts must be tight enough to have  proper hold. Any parts that require regular replacements like conical nozzle, chrome nozzle, lens, etc. must be changed.

Conclusion

The fiber laser machine can serve you for years if it is well maintained. Regular checking of parts reduces the chances of failure. This will save time and money that goes behind those repairs. Also, use the materials that are compatible with your laser machine or else it can damage the machine as well.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/top-5-tips-to-maintain-a-fiber-laser-cutting-machine

3 Types of Laser Cutting Machine

Laser cutting has been in the market since decades now and has been updated a lot in these years. The lasers use a constant beam of light to create the heat and pressure to cut, mark, drill, or engrave the material. With the CNC machines, all the processes are stable and precise.

There are different types of laser machines that have different ways to concentrate the light beam and different materials that can be used with it. They are CO2 Lasers, Fiber Lasers, and Crystal Lasers. 

The manufacturers suggest regular maintenance of these machines and usage of good quality spare parts. Thus, it is recommended to use trumpf laser consumables, amada laser consumables, etc. for quality parts.

To know more about different types of lasers, keep reading.

CO2 Laser

A CO2 laser uses a gas mixture of carbon dioxide, nitrogen, hydrogen, and helium to produce a light beam. The gas mixture is filled in a tube that contains mirrors on each ends. One of the mirrors in the tube is fully reflective and the other is partially reflective allowing some light to pass. The invisible light produced comes under the infrared range of the light spectrum.

Usually the CO2 lasers are 25 to 100 watt in power and the wavelength is 10.6 micrometers. To enhance the power of the CO2 beam, oxygen content can be boosted. This can be risky if the machine is not suitable for such enhancements and the operator is new to this technique. The CO2 lasers are the best for non-metallic materials. This laser is commonly used for cutting or engraving wood, paper, leather, fabric, and acrylic plastics.

The other important task to do is to maintain the laser machine. The regular maintenance helps in receiving the precise cuts. The regular change of consumables is the solution. You can easily find good quality trumpf laser consumables, amada laser consumables, etc.

Fiber Laser

The fiber laser amplifies the light beam with the specially designed fibers which are derived from pump diodes. The wavelength is 1.064 micrometers which produces small focal diameters. The fiber lasers are expensive but the maintenance cost is extremely less. 

Also, they have a long service life of 25,000 laser hours. Thus, the life of fiber lasers is far more compared to the other two types. To ensure that the laser has a long shelf life, it is important to maintain it properly. For that, you can regularly check and change the spare parts. You can use good quality trumpf laser spare parts, prima laser parts, amada spare parts, etc.

Fibers are suitable for metal marking and engraving. It is also suitable for non-metals and alloys and even glass, wood and plastic. With variable power, these lasers can deal with a variety of materials.

Crystal Laser

Crystal laser uses nd:YAG (neodymium doped yttrium aluminum garnet) or nd:YVO (neodymium doped yttrium orthovanadate) crystals. The wavelength of the laser is 1.064 micrometers and are useful for medical, dentistry, military and manufacturing. 

The nd:YVO has:

• higher pump absorption
• a broader bandwidth and wavelength for pumping
• shorter lifetime
• higher refractive index
• lower conductivity

The nd:YAG has similar performance but the only difference is that it does not allow high pulse energy as that of nd:YVO. These lasers are useful for both coated and non-coated metals. It can also be used for plastics and ceramics.

Conclusion

All these lasers have their own way of functioning and are suitable for different types of materials. To always receive the same good quality results, it is necessary to have a maintenance schedule. You can make schedules on a daily, monthly and yearly basis. The parts that require replacement must be replaced with the parts from renowned companies. For example, trumpf laser spare parts , amada laser spare parts, etc.  

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/3-types-of-laser-cutting-machine

Laser Cutting vs Plasma Cutting: The Ultimate Comparison

The invention of CNC machines has made the cutting process more efficient compared to manual cutting methods. The manufacturers or the businesses that require cutting processes are highly inclined toward these two most famous computer-controlled processes known as Laser Cutting and Plasma Cutting. There are advantages and disadvantages that both these cutting methods have when we compare the thickness of the material, type of material, the precision of the cut, cost, etc. Let us understand both these methods in detail and then compare it to know which suits your business requirement the best.

What is Laser Cutting?

Laser cutting is a cutting technology controlled by computer numerical control (CNC) to slice materials by the amplified laser light. It has a high precision rate as it is controlled by a CNC machine and not manually.

 

The cut is made on the metal by focusing the laser light on a small point using the optics. When the laser light enters the optical lens, it will become smaller and hotter. The temperature at the focused point increases which melts and cuts the workpiece leaving the edge smooth and of a high-quality finish.

 

What is Plasma Cutting?

The plasma cutting involves cutting through electrically conductive materials by using an accelerated jet of hot plasma. It can melt any hard material. It has been in use for decades and is still one of the best cutting methods.

The one thing about plasma cutting is that it works only for electrically conductive materials like stainless steel, steel, brass, aluminum, and copper. Plasma is extremely hot during the process as it uses ionized gas and not naked flame. The temperature is usually determined by the plasma torch. It also uses a CNC machine to control the whole cutting process, leaving smooth finish cuts.

Advantages & Disadvantages of Laser Cutting

Here are some advantages of the laser cutting machine when compared to some general cutting methods:

1. The cuts are so precise and smooth that they can be directly used for cutting without grinding.
2. The laser cutting machine is faster than other cutting processes like plasma cutting.
3. The cutting quality of laser machines is much higher and it leaves behind minimum deformation, low surface roughness, and minimal oblique cutting edge.
4. Apart from metal, it can also be used to cut wood, plastic, rubber, PVC, textile, leather, etc.

However, the laser cutting has a couple of disadvantages as well:

1. The laser cutting machine is a little expensive as the initial investment and the maintenance are costly.
2. Laser cutters have lower efficiency when it comes to thick plates which means it is more suitable for thin plates.

Advantages & Disadvantages of Plasma Cutting

Here are some points where plasma cutting has an edge over laser cutting.

1. It is highly suitable for thick plates. It can achieve high cutting speed when compared to laser and flame cutting.
2. The initial investment is lower compared to lasers. Moreover, the maintenance cost is also low.

 

There are a few disadvantages of the plasma cutting machine which make it less favorable than the laser cutting machines.

1. The plasma cutter has poor perpendicularity and it will leave a large oblique cutting edge.
2. It produces slag at the bottom of the cutting process during the cutting. To maintain the quality of the cut, this slag must be removed by grinding which adds up the labor cost.
3. During the cutting process, it releases harmful dust and arc light.
4. It consumes more cutting nozzles which cost a lot of money.

Laser Cutting Vs Plasma Cutting: Comparison

1. The laser cutting machine makes lesser damage to its workpiece when compared to the plasma cutting machine. The plasma cutter requires frequent changes of consumables like nozzles and torches. The damaged consumable can cause damage to the cutting plate and affect the quality of the cut as well. So while using the plasma cutting machine, ensure to use good quality consumables like amada laser parts, trumpf laser parts, prima consumables, etc.
2. The laser has more focused light whereas the plasma has a slightly larger cutting point. So small cuts are more clearer and precise in laser than in plasma.
3. The speed of the laser cutting is more than that of the plasma cutting machine.
4. The laser cutting machine leaves behind smooth and good quality cuts. Also, it produces less heat during the cutting. Thus, there are lesser chances of thermal deformation of the workpiece, saving the material from any kind of damage. Also, the edge is perfect which avoids any kind of secondary process. The only thing you need to be careful of is the thickness of the plate as plates of higher thickness do not perform well with laser cutters.
5. The accuracy of the plasma cutter is less but the maintenance and environmental requirements for cutting are less compared to laser. So for products that do not require high precision, plasma is the most cost-effective choice as the maintenance cost is low. Good quality consumables like amada parts, trumpf consumables are easily available online. Also, the skill requirement is low and it is easy to operate for the operators.

Conclusion

Every business has its own requirements. Some businesses require the use of non-conducting materials, then for them, laser cutters are the best. On the other hand, some businesses have thick sheets to cut, then for them, plasma cutting is preferable. If the type of material is not the issue then budget might be an issue because just buying the machine is not enough. 

To enjoy getting the best output from the machine, it is important to maintain the machine. You can easily find the amada parts, trumpf and prima parts online. For that, all you need to do is Google “amada laser parts” or “trumpf laser parts” and you will have a list of the suppliers. 

We hope these comparisons will help you choose the cutter that fits best your needs.

Source:

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