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CNC Plasma Lab Report
CNC Plasma Lab Report
Figure 15: Area of the surface by using Measure Inertia in Catia ................................................ 14
1.0 TITLE
ADVANCE MANUFACTURING (CNC Plasma)
2.0 OBJECTIVES
2. To study how to use the machine to produce the product through the CNC process.
4. To be able to use the computer programming to set up the product and subsequently
3.1 Theory
The plasma cutting process is a process that cuts materials by creating an electrical overheating
channel that produces hot plasma. The plasma is blown through a nozzle into the material at high
speed
When the electricity of the cutting torch moves along the plasma, it provides enough to melt the
piece. At the same time, high-speed plasma and compressed gas blow hot molten metal, thus
cutting the piece. Because plasma cutting produces a very hot cut that is easy to cut, it is useful
for cutting sheet metal with a curved or angled design.
APPARATUS DESCRIPTION
Advantages:
Durable Performance.
Powder coated metal surfaces.
High Powered Flexibility.
Easy-to-operate software
control
Figure 13: Hornet LT CNC Plasma Cutter
5.0 EXPERIMENTAL PROCEDURE
1) The design of the product is drawn in Catia software in 3D with the maximum size of
100mm X 100mm.
2) The design was change into drawing sheet. The drawing then saved in .dxf format.
3) The FastCam software then opened, click on “Files” and then click on “DFX Restore”
and button “Enter” was clicked.
4) Find the product design in .dxf format and then click the “Select” button. The design then
is saved in flash drive.
5) The flash drive that contain the product design is connected to the CNC plasma machine.
6) The coordinate coding system for the product design was transferred to the CNC plasma
machine to read.
7) Before cutting process is held, a test to trace the place where to cut the product was run.
8) When the test was finished, cutting process was started with the speed of 1500rpm.
9) The product then going to cooling process by flowing water onto the product.
10) The product was then went to finishing process after the cutting process is finished where
we need to grind the product to make it look good and perfect.
11) The product was sketched on a piece of paper and was brought to metrology laboratory to
calculate and measure the area of the product by using digital planimeter.
12) Recorded area is to differentiate the original area of the product and the cutting product
area.
6.0 RESULT & DATA ANALYSIS
3
1
2 Overcut
G92 X0.Y0.
G21
G91
G00 X39.198 Y34.722
G41
M07
G01 Y5.
G03 I-7.071 J-7.071
G03 X-7.071 I-3.536 J-3.536
M08
G40
G00 X7.071 Y23.631
G41
M07
G01 Y5.
G03 I-7.071 J-7.071
G03 X-7.071 I-3.536 J-3.536
M08
G40
G00 X38.563 Y-24.922
G41
M07
G01 X3.535 Y3.535
G03 X-17.008 Y21.8 I-22.475 J0.
G01 Y-43.6
G03 X17.008 Y21.8 I-5.466 J21.8
G03 X-4.999 Y5. I-5. J0.
M08
G40
G00 X-70.234 Y-2.395
G41
M07
G02 X4.454 Y14.191 I33.135 J-2.605
M08
G40
G00 Y-33.592
G41
M07
G02 Y33.592 I28.682 J16.796
G02 X28.681 Y13.204 I11.871 J11.966
G02 Y-60. I16. J-30.
G02 X-28.681 Y13.204 I-16.81 J1.238
G02 X-4.454 Y14.191 I28.682 J16.796
M08
G40
M02
6.2 Area Measurement of Final Product
Experimental Value
Theoretical Value
= 47.92 𝑐𝑚2
Percentage of error
= 7.93 %
7.0 DISCUSSION
From the experiment we can see defects that are present on the final product. Firstly, we have
edge dross on the left of the product. This happens because of the CNC machine need to reduce its
speed when making acute direction change like right angle. Thickness of the steel plate, the speed
of cutting, its ampere also the material composition effects the defects. This is one of the defects
that hard to be prevented as it may be reduced by correcting the drawing before cutting.
Not just that, on the right top eye side there is overcut. Overcut happens when the CNC machine
cut more than it should be cut. In a way which it couldn’t be doing that but as a machine it may
sometimes have it flaws. Maybe the presets on the machine that caused it to act like that. Other
effects maybe the steel plate surface is unsmooth and cause it to effect while cutting.
Lastly, some positive and negative cut angle are present on the product. Negative cut angle is when
it is smaller which goes undercutting while positive angle when the sample is smaller than bottom.
The negative level is caused by slow cutting speed, less torch standoff and high ampere. For
positive angle, it may be caused by low amperage, too high torch standoff and shabby nozzle. All
the defects caused the product to become imperfect and can be discusses.
The area is then calculated and been compared with the theory. The area of the product is 47.92cm2
which is bigger than its theoretical area in the Catiya which is 44.12cm2. Then the percentage error
of the area was calculated and got 7.93%. This number shows that the experiment is a quite success
as it shows just a little percentage error.
8.0 CONCLUSION
This experiment was a complete success, the conclusion is that we can finally achieved the
objectives of the experiment. We get a new knowledge on CNC plasma cutting from its preparation
process and its cutting stage. We can able to know the types of defects that happens on the product
after the experiment. Our products give less defects as the percentage error compared to the
theoretical area is less which is less than 10%.
CNC plasma cutting is one of the advance machinery that can be used for all engineers and students
for easier the works in manufacturing and industries in the future.
9.0 RECOMMENDATION
Website
1. Casting Defects. Retrieved from
https://www.slideshare.net/BhanuChandar4/casting-procedure-defects
Journal
1. Serope Kalpakjian & Steven R. Schmid, Manufacturing Processes for Engineering
Materials, 4th Edition, Illinois Institute Of Technology, Prentice Hall, 2003.
11.0 APPENDICES