Plasma cutting
Efficient Programming for Plasma Cutting Machines with Almacam Cut Software
Drawing from extensive experience, Alma has been at the forefront of plasma cutting technology for many years. Widely adopted in industries dealing with half-thickness sheet metal, particularly in shipbuilding, plasma cutting has served as a catalyst for numerous innovations in programming methodologies developed by Alma. These include continuous cutting without lead-ins/outs and advanced bevel programming techniques. In addition to flat cutting, Alma's software for 3D and beveled cutting also incorporates plasma cutting processes, showcasing Alma's commitment to providing comprehensive solutions for diverse cutting needs
The Technological Process
The plasma cutting process involves localized fusion through an electric arc. This energy is concentrated into a jet of ionized gas known as plasma, directed at high velocity onto a precise point on the metal surface of the part. The intense thermal energy of the arc, reaching temperatures of up to 20,000°C, along with the kinetic energy of the jet, melts the metal at the point of impact and expels the molten material from the cut area
Primarily utilized for medium thickness sheets (ranging from 10 to 30 mm), plasma cutting can effectively cut any electro-conductive material with thicknesses between 0.5 mm and 160 mm. With cutting precision typically around 0.2 mm, it enables the production of bevels. This process offers several advantages, particularly valued in the ship-building industry, including minimized deformation, high cutting speeds for small to medium thickness sheets, the ability to utilize multiple torches, and minimal burring on cut materials
Substantial Material Savings Achieved
- Significant decrease in loss rates facilitated by the high-performance automatic nesting feature, offering a variety of available strategies
- Efficient utilization of remnant sheets or off-cuts of any shape
Reduced Programming Time
- Option to operate in full automatic mode, streamlining programming processes
- Management of repetitive nesting and sub-nesting (kits), facilitating the future reuse of optimized programs
- Capability to adjust profile characteristics (lead-ins/outs, bevels, etc.) without altering the geometry, enhancing programming flexibility.
Reduced Consumable Costs
- Decreased number of sheet drillings due to various cutting methods: continuous cutting (bridges), common cut, etc.
Enhanced Time Efficiency and Comprehensive Safety Measures
- Enhanced computation of tool paths for optimized efficiency
- Decreased cycle times through various methods, such as utilizing bridges between parts and common cut, to eliminate the need for drilling by profile
- Automatic positioning of lead-ins/outs to prevent collisions with previously cut parts
- Height control feature enables straight or beveled cutting
Comprehensive Mastery of Technological Processes and Advanced Machinery
- Control of programmable beveling heads, including automatic program preparation: pass sequence and offsets computation, automatic generation of reconfiguration loops or lead-ins/outs, and creation of an overall profile considering the maximum bulk of the part in nesting, along with allocation of cutting conditions based on angle
- Comprehensive support for all processes combinable with plasma cutting, including drilling, sand-blasting, and various marking systems (alphanumeric marking by ink jet or plasma, etc.).
- Seamless interaction with combined machines (plasma and drilling).
- Support for complex machinery, including those used for machining flat panels in shipbuilding, symmetrical cutting, bottom side marking, pseudo parallel cutting, and more."
An Approach to Enhancing the Quality of Manufactured Parts
- Heat deformation considerations implemented through various automatic or semi-automatic functions, such as heat distribution over the sheet with specific cutting sequences.
- Automatic generation of lead-ins/outs (position, type, length, and angle) based on material and thickness, with automatic correction of inaccurate lead-ins/outs
- Implementation of overlapping at the end of cutting to prevent burrs.
- Precise parameter management tailored to cutting conditions, including gas type, amperage, and nozzle specifications
- Expertise in cutting circular holes with precision
Strategies for Workshop Handling Facilitation
- Hierarchical nesting employing priority groups for streamlined part sorting during evacuation
- Implementation of skeleton cutting to ease remnant evacuation.
- Utilization of plate straps to secure specific inner profiles, preventing deformation issues during part handling