切割自动化领域的合作伙伴
 

Plasma cutting of complex welding surfaces

For a long time, activities of MicroStep company have been focused on development and production of technological nodes of CNC centres for spatial parts cutting using plasma, oxy-fuel, high-pressure water jet and solid-state laser cutting technology. The technological nodes are designed to produce V-, Y-, and K-type cuts needed for subsequent welding processes, generally with variable bevel angles. Typical applications include cutting parts of various domical shapes and profiles of different cross-sections. The applications typically comprise cutting of openings that represent intersections of these geometric shapes. Application area of the CNC systems is exceptionally wide and includes essential areas of industry such as production of tubular structures and piping systems for construction, shipbuilding, automotive industry, manufacturing of technological equipment for chemical industry, power industry, etc.
 
The world market exhibits rapidly growing interest in such systems because they have a strong potential to contribute significantly to growth of production efficiency by removing slow conventional machining methods. The systems represent complex solutions that incorporate development of machine frames and control systems for cutting heads equipped with appropriate sensory subsystems for identification of spatial orientation and contour deviations of the cut parts from ideally declared geometric shapes.
 
The technologies implement algorithms that perform spatial adaptation of cutting tools so that technological cutting parameters are maintained and high accuracy of cutting surfaces is achieved. The control algorithms are required to compensate for errors originating in inherent properties of a particular cutting technology (e.g. a bevel due to the shape of the plasma arc or water jet, etc.). The cutting technologies also involve CAM systems for cutting plans creation as well as cutting plans management system and automatic production control system.
 
Cutting machines designed for cutting spatial parts are equipped with bevel cutting heads (so-called rotators) that provide tilting of the plasma cutting torch in the cutting process. It is important to understand that in the case of bevel cutting the final accuracy of cut parts is influenced by significantly more factors than in the case of straight cutting.
 
Accuracy of bevel cutting is substantially influenced by:
  • mechanical accuracy of the machine kinematic chain,
  • flatness or deviation from ideally declared shape of cut material (inaccuracy of 3D parts), thermal deformations due to cutting process and associated accuracy of keeping constant cutting tool offset
  • technological accuracy of melting off the material (the shape of the cutting kerf)
  • focusing accuracy of the plasma beam
 
Mechanical accuracy of a cutting machine is determined on one hand by accuracy of individual nodes of the kinematic chain and on the other hand by accuracy of the plasma torch attachment.
 
Due to technological reasons collisions of the torch with the material in the process of cutting occur quite frequently. Even though the torch is carried in an anti-collision holder, it does not guarantee a precise return of the torch into the preset position after the collision situation is cleared. For maintaining high cutting accuracy it is often inevitable to adjust the torch position mechanically. The process is quite tedious and decreases production efficiency of the cutting machine. All inaccuracies of the kinematic chain are finally expressed in terms of an error between the actual position of the torch tip and the programmed position. In real devices, when cutting bevel angles around 45

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