Home / Laser, Waterjet, Plasma Cutting Systems

Laser, Waterjet, Plasma Cutting Systems

A yearend review of some of the current advances and application capabilities in each of these metal cutting technologies.

Posted: November 5, 2014

An Eagle fiber laser cutting head with laser beam from MSS Lasers is one of the most advanced systems in the market, with linear drives on all three axes and a low inertia carbon fiber transverse bridge construction that can accelerate up to 6G with achieve cutting speeds in excess of 100 m/min.

Accuracy inside the Eagle fiber laser from MSS Lasers is assured through the rigidity of the carbon fiber bridge and the dynamic polymer concrete frame that minimizes vibration and heat related deflection of the machine geometry. With bed sizes up to 6 m x 2.5 m, this system increases material utilization by efficiently nesting jobs and cutting very large parts.

The SUPER TURBO-X laser-cutting system with Preview 3 control from Mazak Optonics uses proprietary vibration dampening frame and integrated laser resonator that ensure stable, high accuracy cutting of plates. The constant beam length construction provides uniform cutting performance across the machine table.

The TruLaser 8000 2D laser cutting machine from TRUMPF can process material up to 52 ft long and up to one inch thick using a 6 kW laser, making it ideal for processing very large parts or for job shops looking to expand their capacities and range of services.

KBM separate rotor and stator packages on ProLaser CL laser cutting systems from Proteck are supplied in kit form and directly mounted on the machine within their own bearing system and protective cover, with power and encoder connectors built-in. The mounting arrangement directly couples the large diameter pinion shaft to the rotor as a single solid assembly, restricting lost motion and potential unwanted harmonics that a flexible coupling may allow.

On ProLaser CL laser cutting systems from Proteck, S700 servo drives with multi-feedback capability from Kollmorgen are used with both resolver feedback, mounted on the KBM motor for commutation, and magnetic linear scales for the position loop. The feedback protocol is SSI absolute, EnDAT or alternatively BiSS, to suit a choice of CNC controllers with set-up and monitoring via EtherCAT that is integrated in all S700 drives.

With a maximum sheet size of 3.1 m x 1.6 m, next-generation ProLaser CL flat sheet cutting machines from Proteck also use AKM series rotary servo motors with Micron™ series planetary gearheads that are brake fitted for the Y-axis as well as the Z-axis.

The highly rigid MicroMAX JetMachining® Center from OMAX has a table size of 2 ft 4 in x 2 ft 4 in and an X-Y cutting travel of 2 ft x 2 ft. Its new Mini Tilt-A-Jet® cutting head nearly quadruples the position accuracy of the nozzle for even more precise cutting with virtually zero taper in most materials up to 3 in thick. The head is also 25 percent smaller and lighter and nearly twice as rigid for less deflection.

Intelli-MAX 21 for JetMachining Centers from OMAX not only optimizes tool paths automatically, it provides precise predictability of cutting speeds, taper, jet lag and other abrasivejet factors of those particular tool paths to achieve the highest levels of waterjet cutting speed and performance.

Supplied with a MAXJET 5i nozzle, the high precision A-Jet cutting head from OMAX cuts accurate beveled edges at angles determined by either the machine operator or part program. The A-Jet adds two motion axes, enabling the nozzle to tilt over a range of 0 deg to 60 deg from the vertical position. It can be used to easily produce beveled edges or cut countersunk holes, as well as machine parts with complex geometries. With its additional axes of motion, the A-Jet allows production of beveled edges in preparation for welding operations. The use of this accessory eliminates the need for many secondary machining and grinding operations.

With a Rotary Axis, JetMachining Centers from OMAX have up to 6-axis cutting capabilities that can create accurate complex 3D parts from pre-existing CAD drawings or DXF files. With the expanded parametric shape library, the Rotary Axis is ideal for pipe and tube cutting, simplifying challenging projects such as intersecting pipe fittings.

FlowXpert 2015 is a robust CAD/CAM software platform from Flow International that introduces significant new waterjet capabilities for 3D pathing and cutting that allow shops to work more effectively and with less complexity in 3D.

The DynaBeam laser height sensing technology from Flow maps the natural state of materials, reducing the need for manual adjustment throughout cutting. Operators can choose between setting the standoff height between the waterjet nozzle and the workpiece before every pierce, or pre-mapping an entire workpiece quickly and easily.

The price of a build-it-yourself WARDKit from WARDJet includes everything necessary to start waterjet cutting, including the tank, cutting head, grates, intensifier pump, control software, human machine interface and access to technical support. Upgrades and options on pump horsepower, controller style, and abrasive delivery system allow perfect configuration.

The Emerald 0606, the smallest waterjet ever manufactured by WARDJet, is designed to offer all the quality of a large, expensive waterjet cutting system at a reduced size and cost. Because of its rigid, sturdy tank design, the Emerald 0606 is capable of handling 12 in thick stainless steel just as easily as a 2 in sheet of foam.

The J-Series is a low-cost water-only waterjet from WARDJet that uses belt drive technology to cut at speeds of 2,500 ipm with an acceleration and deceleration rate of 0.2 m/s2. J-Series waterjets are ideal for cutting high volumes of parts where margins are low and tolerances are not as demanding.

The L-Series, the fastest cutting waterjet from WARDJet, uses a linear motion drive system with excellent accuracy, repeatability and reliability that cuts 7,000 ipm with an acceleration and deceleration rate of 1 sq m. The thick-walled steel tubing frame of the L-Series can accommodate multiple 5-axis cutting heads.

The FARM-JET waterjet cutting system from Jet Edge brings the power and versatility of ultra-high pressure waterjet cutting technology to farm machine shops for the price of a new fully loaded 1 ton 4X4 pickup truck, without requiring special electrical service.

The affordably priced direct-drive style Eco-Jet PTO ultra-high pressure waterjet pump is ideal for rural machine shops or areas with limited power because it utilizes a tractor PTO shaft to produce ultra-high pressure water for precision cutting, cleaning and surface preparation. It runs a .015 in waterjet orifice and can power most waterjet cutting systems and waterjet tools.

The economically priced BOSS-CUTTER water jet cutting system from Jet Edge is ideal for small shops. It has a 40 in x 40 in (1 m x 1m) work envelope with one abrasivejet cutting head and a motorized Z-axis with 5 in (513 mm) of travel that is controlled with a Windows PC (sold separately) and uses a FlashCut Pro-Series Stepper Controller and FlashCut CNC software. It also includes IGEMS path generation software and a hand-held controller pendant for operator convenience.

The compact SGX automated plasma and oxy-fuel cutting machine from ESAB features the easy-to-use Vision® T5 touch-screen CNC with built-in automatic nesting, as well as automatic gas controls and plasma automation powered by m3 Plasma technology. Performance and accuracy are assured with a heavy steel beam, precision machined mating surfaces, and linear rail. This rugged design ensures smooth motion, accuracy and long term machine durability. SGX enables higher productivity with rapid cut-to-cut cycle times through the integration of dual-side, high-speed AC drives and a fast torch lifter.

The do-it-yourself V Series Plasma from MultiCam features a custom-engineered, extruded aluminum frame with steel leg supports for high strength and rigidity. Automatic torch height is standard along with powerful, dual X-axis drive motors and Hypertherm PowerMax plasma torches. The easy-to-use, handheld operator interface features graphic icons for all machine functions.

The V-PRO CNC Plasma system from MultiCam has a standard, heavy-duty, all-steel water table with integrated bladder capable of production processing of sheet steel up to 1.25 in thick without the need for fume evacuation. The CNC plasma system uses a Hypertherm MAXPRO200 (200 amp) power supply engineered for heavy-duty, high capacity mechanized cutting.

The compact, durable 5-axis bevel plasma head from MultiCam uses aluminum castings for weight reduction and rigidity, has improved crash protection and ease of maintenance, and introduces the “phi” and “theta” axes of movement for cutting complex parts with bevels up to 45 deg in 2 in thick mild steel.

Designed to remove up to 25 lb of metal per hour, the PAK 200i manual gouging and plasma cutting system from Victor Thermal Dynamics can also hand cut 2 in thick mild steel at 10 ipm.

Steven Cranston of Alliance Automation said, “This robotic waterjet trimming cell features numerous design innovations that distinguish it from other robotic systems and promise to increase productivity, lower operating costs and improve worker safety. The system lowers operating costs by eliminating the need for complicated trimming dies. It is set up so that many different parts can be programmed to make a quick change of tools or products. Jobs also can be installed with multiple parts to maximize productivity. In addition, the innovative design of the coil package on the robots allows for a quick change. All coils are a standard design (for each specific robot model), factory wound, pre-coned and pre-threaded.”

Established in 1984, Jet Edge is a global designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal that are used around the world in a broad range of industries, from the world’s leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops.

Jet Edge, Inc., 12070 43rd Street N.E., St. Michael, MN 55376-8427, 763-497-8700, sales@jetedge.com, www.jetedge.com.

PLASMA CUTTING

COMPACT, AUTOMATED PLASMA AND OXY-FUEL CUTTING
ESAB Cutting Systems (Florence, SC) offers the compact SGX, an automated cutting machine for plasma and oxy-fuel cutting. The system is designed with leading-edge technology made affordable for the small fabricator or manufacturer. SGX is a rugged, high-performance machine that carries up to three tool stations, including up to two oxy-fuel torches and one plasma station that can be equipped with the m3-IGC Precision Plasma System for high-quality plasma cutting.

The compact design of the SGX cutting machine minimizes floor space requirements. One-meter rail increments keep the footprint small to maximize production space. Simple, automated operation is achieved with the built-in process database in the Vision T5 CNC, which fully integrates ESAB plasma and oxy-fuel process controls into an easy-to-use touch-screen interface.

The oxy-fuel gas control automatically switches between low preheat and high preheat pressure. Ease-on cutting oxygen allows for piercing of thicker materials. Gas controls are conveniently located at the side of the machine where the operator has easy access and can see the torches while making adjustments.

SGX can be configured with a wide range of plasma options, from simple air-plasma systems up to fully automatic 360 Amp multi-gas plasma systems. The machine can be equipped with m3 Plasma® for cutting up to 50 mm (2 in) thick mild steel. The m3 Plasma system achieves superior cutting results over a wide range of material types and thicknesses, and produces a high quality cut face with low dross, requiring little secondary clean up. It features an automatic gas control integrated with the process database on the CNC for fast and easy process setup without the guesswork.

SGX is available in sizes to cover plates up to 2,500 mm (8 ft) wide, and up to two 6,000 mm (20 ft) plates end-to-end. This cutting system is offered with a choice of downdraft tables or water tables for dry or under-water plasma cutting.

For more than 75 years, ESAB has been a total system supplier that offers off-the-shelf, turnkey CNC shape cutting machines in a variety of sizes, using a wide range of cutting technology to include plasma, oxy-fuel, laser, and waterjet tools, programming and nesting software, and CNC controls, to customers around the world.

ESAB Cutting Systems, PO Box 100545, 411 South Ebenezer Road, Florence, SC 29501, 843-664-5618, szlotnicki@esab.com, www.esab-cutting.com.

ASSEMBLE YOUR OWN CNC PLASMA
The V Series Plasma from MultiCam Inc. (Dallas, TX) is designed for companies looking for maximum value in a CNC plasma machine. It is ideal for both entry-level as well as experienced manufacturers and anyone on a budget. The machine is now offered in an even more economical, easy-to-ship kit form. Easy-to-understand instructions are provided on DVD and the machines can be assembled and ready to operate in approximately 4-6 hours. EZ-G code and EZ-Suite application software is included with all machines to quickly convert drawings to machine code. And V-Series machine support and technical assistance is provided by a local MultiCam Technology Center to insure your investment.

MultiCam also offers the V-PRO CNC Plasma system that features a standard, heavy-duty, all-steel water table with integrated bladder capable of production processing of sheet steel up to 1.25 in thick without the need for fume evacuation. The CNC plasma system comes standard with a Hypertherm MAXPRO200 (200 amp) power supply engineered for heavy-duty, high capacity mechanized cutting. The V-PRO motion platform is isolated from heat built up in the cutting tank resulting in smooth, precise cutting of all material thicknesses. Automatic torch height is a standard feature and EZ-G code software is included for easy conversion of CAD drawings to machine-ready G-code.

The company also offers a new 5-axis bevel plasma head for maximum performance that uses aluminum castings for weight reduction and rigidity. The new plasma head is not only a compact, durable cutting solution, but its innovative features provide for improved crash protection, as well as ease of maintenance. Its advanced technology provides for maximum table coverage which leads to a more flexible machine.

Although all MultiCam plasma machines have the capability to move simultaneously in the X, Y and Z axes, this new 5-axis bevel plasma head introduces two additional axes of movement, the “phi” and “theta.” These two axes allow operators to cut complex parts with bevels up to 45 deg in 2 in thick mild steel. The new 5-axis bevel plasma head was designed with the upgrade-ability of existing plasma systems in mind.

All bevel plasma systems come standard with Automatic torch height control (ATHC) along with EZ-G-Code 5-axis software for use with an existing 3-axis CAD/CAM system. In addition, all machines are fully compatible with SIGMANEST and Hypertherm ProNest 5-axis bevel CAD/CAM systems. MultiCam has over 70 Technology Centers worldwide that sell, service and support its products.

MultiCam Inc., 1025 W. Royal Lane, PO Box 612048, Dallas/DFW Airport, TX 75261, 972-929-4070, Fax: 972-929-4071, marketing@multicam.com, www.multicam.com.

MANUAL CUTTING AND GOUGING FOR DEMANDING APPLICATIONS
Plasma arc gouging is a fast, economical, and environmentally friendly method of removing just about any metal: carbon steel, stainless steel, cast iron, aluminum, brass and bronze. Victor® Thermal Dynamics® (St. Louis, MO) has launched an improved PAK 200i manual plasma cutting and gouging system that has the capacity to satisfy the most demanding manual plasma application requirements. The system delivers 100 percent duty cycle at 200 amps, is capable of hand cutting up to 2¾ in (70 mm) on mild steel, as well as 10 ipm (254 mm/min) on 2 in (51 mm) carbon steel, and will remove up to 25 lb (11.3 kg) of carbon steel per hour.

“The PAK 200i is one of the most powerful manual cutting and gouging systems on the market today,” says Michelle Chamberlain, the brand manager. “It provides exceptional cost-performance benefits along with the same great reliability, simplicity, productivity and versatility of the PAK 200.” The PAK 200i now shares the same case and common platform with the company’s other 200 amp products.

Exclusive to the PAK 200i and particularly useful for gouging applications is the Tip Saver Plus feature. With accidental tip-to-work piece contact, the current will fold back to 35 Amps to ensure that the tip is not damaged, dramatically extending tip life. Other features include dual gas capability for superior cut quality and control on stainless steel and aluminum. The system, with a standard 2-year parts and labor warranty, can be configured to operate at 380-415V, 480V or 400V CE (European and Asian operation).

The PAK 200i system comes standard with the PCH 200 handheld torch, featuring a 70 deg or 90 deg torch head angle. The company also offers a 180 deg torch for mechanized applications, such as pipe beveling. Other applications include general fabrication, over the road transport trailers, railroad maintenance, vessel manufacturing, pipe beveling and fabrication, petroleum refineries, foundries, chemical plants, mining operations and ship building. When compared to conventional air carbon arc gouging, plasma arc gouging with the PAK 200i offers superior removal rates and clear visibility of the gouging area.

Victor Technologies, 16052 Swingley Ridge Road, Suite 300, St. Louis, MO 63017, 636-728-3000, victortechnologies.com.