PROFILE CUTTING OF METALS ON CNC PLASMA

MACHINE
A PROJECT SUBMITTED

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD

OF

Bachelor of Technology

In

MECHANICAL ENGINEERING

Submitted By

D.KRANTHI KUMAR REDDY (13E51A0332)

CH. SHIVA SHANKAR RAO (13E51A0328)

S. SAI KIRAN GOUD (13E51A03A8)

Under the esteemed guidance of

Mr. G. Venkatesh

(Asst.Professor)

DEPARTMENT OF MECHANICAL ENGINEERING

HYDERABAD INSTITUTE OF TECHNOLOGY AND MANAGEMENT

OFFICE: 1-1-191/A, 1st Floor, Above ING Vysya Bank, Chikkadpally, Hyderabad - 500 020. India.
Phone: +91-40-66251148/ 3882. 
CAMPUS: Gowdavelly (Village), Medchal (Mandal), Ranga Reddy (Dist.) - 501401, AP India.
Tel: +91 8418-200074, Fax: +91-8418-200528.

2016 – 2017

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 DECLARATION

This is to certify that the work reported in the present thesis titled “Study of steam turbines-
High pressure moving blades” is a record of work done by us in L&N STRUCTURAL
ENGINEERS PVT. LTD. 48/C, Phase-1, IDA, Jeedimetla, Hyderabad-500055.

No part of this thesis is copied from any person/project/university and

wherever the portion is taken, the same has been duly referred in the text. The report is based
on the project work done entirely by us and not copied from any other source

D.KRANTHI KUMAR REDDY (13E51A0332)

CH. SHIVA SHANKAR RAO (13E51A0328)

S. SAI KIRAN GOUD (13E51A03A8)

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 CERTIFICATE

This is to certify that the project report entitled “PROFILE CUTTING

OF METALS BY USING CNC PLASMA MACHINE” that is being submitted by Mr./Ms
D. KRANTHI KUMAR REDDY (13E51A0332), CH. SHIVA SHANKAR RAO
(13E51A0328), S. SAI KIRAN GOUD (13E51A03A8) in partial fulfilment for the award of
The Degree of Bachelor of Technology in Mechanical Engineering to the Jawaharlal Nehru
Technological University is a record of bonafide work carried out under my guidance and
Supervision. The results embodied in this project report have not been submitted to any other
University or Institute for the award of any degree or diploma.

Date:

(Internal Guide) (Head Of The Department)

G.Venkatesh K.VENKATAPHANI BABU
Dept. of Mechanical engineering, Dept. of Mechanical Engineering
HITAM, Gowdavelly, HITAM, Gowdavelly,
Hyderabad. Hyderabad.

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 ACKNOWLWDGMENT

I convey my sincere thanks to our principal Dr.S.V.S RAMA KRISHNAM RAJU for
providing me the required infrastructure and a very vibrant and supportive staff.

I would like to thank our honourable Head of the Department of Mechanical Engineering,
Prof.K.VENKATAPHANI BABU for his masterly supervision to all the phases of the
project work with his valuable suggestions.

I thank my internal guide, Asst.Professor G.Venkatesh for encouraging me I

successfully commencing the project work.

I express my sincere thanks to our external guide Mr.Ramesh for his constant
encouragement and support throughout our course and especially for the useful suggestions
and guidance during the commencement of the project.

The satisfaction and euphoria that accompany the successful completion of the task would be
great but incomplete without the mention of the people who made it possible with their
constant guidance and encouragement crowns all the efforts with success. In this context, we
would like to thank all the other staff members, both teaching and non-teaching, which have
extended their timely help and eased our task.

With Regards

D.KRANTHIKUMAR REDDY (13E51A0332)

CH.SHIVA SHANKAR RAO (13E51A0328)

S.SAI KIRAN GOUD (13E51A03A8)

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 ABSTRACT

Cutting is an important manufacturing process that is used in a wide range of

applications. From aerospace applications to the manufacturing of automobiles and robots,
we see a major role. Now a day’s automation is playing an important role in industrial field.
Usually we used to control the industrial equipment’s by manual operation, which increases
the human effort and maintenance cost. To overcome this process CNC machines were
introduced.

A Computer Numerical Control or CNC system controls many machine functions and
movements which were traditionally performed by skilled and programmed automated
machines. It developed out the need to meet the requirements of high production rates,
uniformity and consistent part quality.
In this project we focus on gaining an improved understanding of cutting
techniques of CNC plasma cutting. We acquired primary machine shop skills that provided
us an opportunity to cut a class of jobs to specified dimensions.
For each component, we created a detailed engineering drawing that helped to
shape and construct all the operations and procedures that must be undertaken and controlled
to attain accuracy. The main relevant factors that we examined were CNC Programming,
consumers selection, gases. The extent to which these factors can influence machining is
presented.

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 CONTENTS
Chapter-1: Introduction of CNC Machines

1.1.Introduction

1.2.Types of CNC Machines

1.3.Programming of CNC Machines

1.4.Pros. & Cons. Of CNC

Chapter-2: Layout of Plasma System & Components

2.1. Plasma system components

2.2. Air Compressor

2.3. Air Filter

2.4. Stabilizer

2.5. Sensors

2.6. Plasma Controller (Hi-Focus)

2.7. Machine Bed

Chapter-3: Introduction to Plasma

3.1. Introduction of Plasma Torch

3.2. Consumables of Plasma Torch

3.3. Functions of each Consumable

3.4. Description & Principle of Plasma Arc Cutting

3.5. Work Involved in Plasma Arc Cutting

3.6. Flow Process

3.7. Auto CAD Design

3.8. Nesting Process

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Chapter-4: Materials Used in CNC Plasma Cutting

4.1. Mild Steel

4.2. Stainless Steel

4.3. Aluminium

Chapter-5: Conclusion

Chapter-7: References

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 CHAPTER-1
INTRODUCTION TO CNC MACHINE
(Computer Numerical Control)

1.1. Numerical Control

Numerical Control is the automation of machine tools, they are operated by
precisely programmed command encoded on a storage medium but performing the
calculation and encoding the data is done by human which is complex to operate and prone to
error.

In order to overcome this method NC programming is fed into the computer which reduces
human errors and increases efficiency i.e. CNC (computer numerical control).

CNC

Computer numerical control (CNC) machining is a technology which has been in existence
for some decades and is reaching to the highest point in the history of machine tool evolution
in sophisticated CNC manufacturing operation. Machine parts are first designed on the
Computer–Aided –Design (CAD) software. The same drawing is then use to create the CNC
part program automatically.

Computer Numerical Control (CNC) is a specialized and versatile form of Soft

Automation and its applications cover many kinds, although it was initially developed to
control the motion and operation of machine tools.

Computer Numerical Control may be considered to be a means of operating a machine

through the use of discrete numerical values fed into the machine, where the required ‘input’
technical information is stored on a kind of input media such as floppy disk, CD ROM, DVD,
USB flash drive, or RAM card etc. The CNC machine uses coded instructions that are sent to
an internal computer, which allows factories to fabricate parts accurately and quickly. There
are many different types of CNC machines, ranging from drills to plasma cutters, so they can
be used mostly to make a wide variety of parts in manufacturing industries.

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 Fig: 1.1 Fig: 1.2

1.2. Types of CNC Machines

The most common CNC machines are milling machines, lathes and grinders.

A) CNC Milling Machine

Milling machines automatically cut materials, including metal, using a
cutting spindle, which can move to different positions and depths as directed by the
computer instructions.

B) CNC Lathe Machine

Lathes use automated tools that spin to shape material. They are
commonly used to make very detailed cuts in symmetrical pieces, like cones and
cylinders.

C) CNC Grinding Machine

Grinders use a spinning wheel to grind down materials, and mold

metal or plastic into the desired shape. They are easy to program, so they are usually
used for projects that do not require the same precision as mills or lathes.

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1.3. PROGRAMMING OF CNC MACHINE
The code used to program CNC units is generically called G-Codes and M-Codes. It contains
information about where parts of the machine should be positioned, and tells the machine
exactly where to place a tool. Other instructions tell the machine additional details, like the
speed a part should run at, how deep it should cut, burn, or punch and the angle of an
automated tool. Most modern industrial CNC machines are tied into a network of computers,
and receive operating and tooling instructions via a software file.

CAM (Computer Aided Machining/Manufacturing)

It refers to the use of various software packages to create tool paths and NC code
to run a CNC controlled machine, based on 3D computer model (CAD) data. When the two
are used together, this is generally referred to as CAD/CAM.

CAM does not actually runs the CNC machine, but just creates codes ( like G-
codes and M-Codes ) for it to follow.

Fig: 1.3

Before CNC

CNC machines typically replace (or work in conjunction with) some existing manufacturing
processes. Take one of the simplest manufacturing processes, drilling holes, for example.

A drill press can of course be used to machine holes. A person can place a drill in the drill
chuck that is secured in the spindle of the drill press. They can then (manually) select the
Then they manually pull on the quill lever to drive the drill into the work piece being

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machined. Desired speed for rotation (commonly by switching belt pulleys), and activate the
spindle.

Fig: 1.4

As you can easily see, there is a lot of manual intervention required to use a drill press
to drill holes. A person is required to do something almost every step along the way! While
this manual intervention may be acceptable for manufacturing companies if but a small
number of holes or work pieces must be machined, as quantities grow, so does the likelihood
for fatigue due to the tediousness of the operation. And do note that we've used one of the
simplest machining operations (drilling) for our example. There are more complicated
machining operations that would require a much higher skill level (and increase the potential
for mistakes resulting in scrap work pieces) of the person running the conventional machine
tool. Therefore to come out of this problem, automated machines are developed.

Advantages
1) CNC machines can be used continuously 24 hours a day, 365 days a year and only to be
switched off for occasional maintenance.

2) One person can supervise many CNC machines as once they are programmed they can
usually be left to work by themselves.

3) CNC machines are programmed with a design which can then be manufactured hundreds
or even thousands of times. Each manufactured product will be exactly the same.

4) Less skilled/trained people can operate CNCs unlike manual lathes / milling machines
etc... Which needs skilled engineers.

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Disadvantages
1) CNC machines are more expensive than manually operated machines, although costs are
slowly coming down.

2) The CNC machine operator only needs basic training and skills, enough to supervise
several machines other than manually operated machines which needs years of training to
operate the machines.

3) Less workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.

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 CHAPTER-2
Layout of Plasma System & its Components

2.1. Power Unit

The power switch boxes are used to switch ON/OFF the machineries which are required for
the cutting operation.

Power supply -- The plasma power supply converts single or three phase AC line voltage
into a smooth, constant DC voltage ranging from 200 to 400VDC. This DC voltage is
responsible for maintaining the plasma arc throughout the cut. It also regulates the current
output required based on the material type and thickness being processed.

Arc Starting Console – The ASC circuit produces an AC voltage of approximately 5,000
VAC at 2 MHz which produces the spark inside of the plasma torch to create the plasma arc.

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2.2. Air Compressor

Air compressor is a device which intakes the air from surrounding environment and converts
it into highly pressurized compressed air by using an electric motor.

When the tank pressure reaches its upper limit, the compressor shuts off and the compressed
air is held in the tank until is used. When the compressor reaches its lower limit again it starts
compressing air. The energy contained in the compressed air can be used for a variety of
applications.
2.3. Air Filter

The air filter is used to remove the contaminants from the compressed air such as water
vapour and pollutants. These are commonly found in a wide range of industrial and
commercial facilities.

This raises the dew point of the compressed air relative to free atmospheric air and leads to
condensation within pipes as the compressed air cools downstream of the compressor.

Air Filter

2.4. Stabilizer
Stabilizer is designed to automatically maintain a constant voltage level. A voltage regulator
may be a simple "feed-forward" design or may include negative feedback control loops. It
may use an electromechanical mechanism, or electronic components. Depending on the
design, it may be used to regulate one or more AC or DC voltages.

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 Stabilizer

2.5. Sensors

A sensor is a transducer whose purpose is to sense (that is, to detect) some

characteristic of its environs. It detects events or changes in quantities and provides a
corresponding output, generally as an electrical or optical signal which is supported by a
stopper in order to prevent the CNC to deviate from its path on the provided track.

2.6. Plasma Controllr (Hi-Focus)

Plasma controller is used to control all of the settings required to run the plasma
cutting process equipment, such as gases, current, arc voltage, coolant flow, cutting speed,
etc.

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 Coolant Inlet

Gas Connections

Coolant Tube

Maintained b/w max. & min.

2.7. Machine Bed

It is a platform on which job is machined as per the required dimensions and design ordered
by the customer. There is no specified and exact size of a platform; it is built according to the
industrial needs and infrastructure of the machine. It is earthen by the copper wires, to form
an electrical arc which is essential in case of plasma cutting.

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 Machine Bed

CHAPTER-3

INTRODUCTION OF PLASMA

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Plasma is obtained when the gases are boosted at extremely high temperatures. The energy
begins to break apart the gas molecules, and the atoms begin to split. Normal atoms are made
up of protons and neutrons in the nucleus surrounded by a cloud of electrons. In plasma,
the electrons separate from the nucleus. Once the energy of heat releases the electrons from
the atom, the electrons begin to move around quickly. The electrons are negatively charged,
and they leave behind their positively charged nuclei. These positively charged nuclei are
known as ions. When the fast-moving electrons collide with other electrons and ions, they
release vast amounts of energy. This energy is what gives plasma its unique status and
unbelievable cutting power.

Fig:3.1

The plasma arc formation begins when a gas such as oxygen, nitrogen, argon, or
even shop air is forced through a small nozzle orifice inside the torch. An electric arc
generated from the external power supply is then introduced to this high pressured gas flow,
resulting in what is commonly referred to as a “plasma jet”. The plasma jet immediately
reaches temperatures up to 40,000° F, quickly piercing through the work piece and blowing
away the molten material.

3.1. Introduction To Plasma Torch

Plasma Torch is a device which is mounted vertically on the cross beam of CNC machine. It
serves as a link between the inlet flow of gases from cylinders and consumers that are

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attached to the bottom end of the torch. This torch is assisted by a sensor which controls the
torch operations.

Fig:3.2

3.2. Torch Consumables

Consumables are the parts which are responsible for optimized flow of gases under varying
pressures, coolant flow, arc formation in case of Plasma and flame In case of oxy-fuel, etc.

Fig:3.3

Protection Cap

3.3. Functions of ach Consumables

1. Cooling tube (for gases flow)

2. Cathode (arc generation)
3. Gas guide (which directs flow of gases through tiny holes)
4. Nozzle (increases velocity of gases)
5. Nozzle cap (protects the nozzle from damage)
6. Swirl cap (permits swirl flow of gases for better combustion)
7. Protection cap (avoids exterior damage, heat loss).

3.4. CNC PLASMA CUTTING

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 Plasma cutting is a process that cuts through electrically conductive
materials by means of an accelerated jet of hot plasma. Typical materials cut by this process
include steel, aluminium, brass and copper though other conductive metals may be cut as
well. Plasma cutting is often used in fabrication and welding shops, automotive repair and
restoration, industrial construction, salvage and scrapping operations. Due to the high speed,
precision cuts, combined with low cost of operation, plasma cutting sees a widespread usage
from large scale industrial CNC applications down to small hobbyist shops.

Fig:3.4 Fig:3.5

The basic plasma cutting process involves creating an electrical channel of superheated,
electrically ionized gas i.e. plasma from the plasma cutter itself, through the work piece to be
cut, thus forming a completed electric circuit back to the plasma cutter via a grounding
clamp. This is accomplished by a compressed gas (oxygen, air, inert and others depending on
material being cut) which is blown through a focused nozzle at high speed toward the work
piece.

Plasma cutting is an effective means of cutting thin and thick materials alike. Hand-held
torches can usually cut up to 38mm thick steel plate, and stronger computer-controlled
torches can cut steel up to 150 mm thick. Since plasma cutters produce a very hot and very
localized "cone" to cut with, they are extremely useful for cutting sheet metal in curved or
angled shapes.

Principle of Plasma Arc Cutting

The basic principle is that the arc formed between the electrode and the work piece is
constricted by a fine bore, copper nozzle. This increases the temperature and velocity of the
plasma emanating from the nozzle.

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The temperature of the plasma is in excess of 20 000°C and the velocity can approach the
speed of sound. When used for cutting, the plasma gas flow is increased so that the deeply
penetrating plasma jet cuts through the material and molten material is removed in the efflux
plasma.

Fig:3.6

The Plasma cutting process operates by using the arc to melt the metal which can be applied
to cutting metals which form refractory oxides such as stainless steel, aluminium, cast iron
and non-ferrous alloys.
This process uses a concentrated electrical arc which melts the
material through a high-temperature plasma beam. All conductive materials can be cut.
Plasma cutting units with cutting currents from 20 to 1000 amperes to cut plates with inert
gas, 5 to 160 mm thicknesses. Plasma gases are compressed air, nitrogen, oxygen or argon/
hydrogen to cut mild and high alloy steels, aluminium, copper and other metals and alloys.

3.5. Working of CNC Plasma Arc Cutting

CNC working process is divided into three categories:-

a) Flow process b) AutoCAD design c) nesting process

3.6. A) Flow Process

This process describes about the flow of power from the main 3 phase current to the power
control unit. From power control unit power is divided to various machines like crane, CNC,
bending machine, air compressor, etc.., Power input to the air compressor is drawn from the
respective panel. Air compressor generates compressed air at an optimum pressure 9.8 bar.
The pressurized air is passed in to the drier which removes moisture from the compressed air
and filters the impurities which is indicated by its dew point temperature.

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Filtered and dry air is fed into the plasma gas control unit which indicates the pressure range
and then to the required torch (i.e., plasma). Required voltage for the plasma (410v) are
prevented from fluctuations by passing through plasma stabilizers .Gases required for the
process are drawn from cylinders with their respective pressures regulated by the valves &
then fed into the plasma gas control unit which indicates the operative real time pressures
and then fed into the respective torches based on the process (plasma and ox fuel).Finally all
the details of gases ,air pressure ,coolant level etc.., are electrically connected to the plasma
control unit which indicates the error.

3.7. Auto CAD Design

In this process drawing is done through AutoCAD software as per the required dimensions.
Designing in AutoCAD involves skill and creativity. Drawings finalized in the AutoCAD
without errors are fed into the nesting software for nesting process.

3.8. NESTING

NESTING is a method which reduces the raw material wastage by proper arrangement of the
work pieces to be cut on the required plate as mentioned in the software. It is the only process
which is essential to convert the cad programmed file format to other format which is
compactable to the CNC machine.
In manufacturing industry, Nesting refers to the process of laying out cutting patterns to
minimize the raw material waste. Examples include manufacturing parts from flat raw
material such as sheet metal. The software analyses the parts (shapes) to be produced at a
particular time. Using proprietary algorithms, it then determines how to lay these parts out in
such a way as to produce the required quantities of parts, while minimizing the amount of
raw material wasted.

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Description of Nesting

In this process work piece which is to be cut is designed in the AutoCAD and it is inserted
into the nesting software. The software we use for nesting is OMNIWIN.

In this software initially a nest plan is to be created representing company name, date,
thickness to be cut.

All these details denote the heading of the file. Then material is to be selected as per the
codes mentioned. Based upon the thickness the process is to be selected (plasma or ox
fuel).Later the dimensions of the raw material on which the profile is to be cut are given
based on the limits of the machine.

After entering the dimensions, the sheet is created. Then open the file location and import the
drawing from cad file and pasted on to the sheet. Depending upon the number of pieces to be
cut profiles are too arranged in an array or manual fashion which minimizes the scrap of
material. Then collision control is given to avoid overlapping of profiles which reduces scrap.
By selecting collision control option we have to enter part to part & part to plate distance in
mm. next part sequence is to be assigned which exhibits cutting of work pieces in an orderly
fashion.
Simulation is to be done to view the process of cutting by lead in and lead out paths. Finally
the file is saved in .xml and .txt format. The CNC screen opens .txt format which when
opened generates G codes & M codes. These codes represent the torch movement in X & y
directions.
The .txt format file is copied in USB an inserted in the CNC screen.

BACK OF CNC SCREEN

CNC SCREEN

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USB Pen Drive
 Fig:3.7 Fig:3.8

In CNC screen select the part program option and choose USB to open the file. After
opening the file, it has to be loaded. The profile appears on the run screen. Select database
option and choose the type of material, cutting current, thickness and press ok. It displays kef,
consumers used and their codes. Now reference points are considered. Machine is to be
checked for dry run which outlines the profile.
Then by selecting automatic mode of run and igniting the torch cutting process is started. The
operator need to observe that there is no torch lift off. After cutting material is to be delivered
as per the requirements.

CHAPTER-4
MATERIALS USED IN CNC PLASMA CUTTING

a) Mild Steel
b) Aluminum
c) Stainless Steel
d) Galvanized Iron

4.1. Mild Steel

Generally, with an increase in the carbon content from 0.01 to 1.5% in the alloy, its
strength and hardness increases but still such an increase beyond 1.5% causes appreciable
reduction in the ductility and malleability of the steel.

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Low carbon steel or mild steel, containing carbon up to 0.25% responds to heat treatment as
improvement in the ductility is concerned but has no effect in respect of its strength
properties.
Fig:4.2
Fig:4.1

Job Scrap Material

4.2. Aluminium
Aluminium is a chemical element in the boron group with symbol Al and atomic number 13.
It is a silvery-white, soft, nonmagnetic, ductile metal. Stable aluminium is created
when hydrogen fuses with magnesium either in large stars or in supernovae.

Fig:4.3

Job Obtained From Raw Material

4.3. Stainless Steel

In metallurgy, stainless steel, also known as in-ox steel, is a steel alloy with a minimum of
10.5%chromium content by mass. Stainless steel does not readily corrode, rust or stain with
water as ordinary steel does. However, it is not fully stain-proof in low-oxygen, high-salinity,
or poor air-circulation environments.

Fig:4.4 Fig:4.5

Job Scrap Material

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4.4. G.I. Sheet
Galvanizing is a process of coating iron or steel with zinc in order to provide greater protect
against corrosion for the iron or steel base.

Fig:4.6 Fig:4.7

Job Scrap Material

CONCLUSION:
Plasma Cutting whether conventional or precision, is a fast, economical way to produce parts.
For cutting of materials by using CNC Plasma Machine, the human effort may be reduced for
mass production and the cutting process involves with definite precision within a short time.

REFERENCE

1. Joseph C. Chen, Ye Li (2009) Taguchi Based Six Sigma Approach to Optimize

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Plasma Arc Cutting Process: an Industrial Case Study. International Journal of

Advanced Manufacturing Technology 41: 760-769.

2. Asiabanpour Bahram (2009) Optimising the automated plasma cutting process

by design of experiments. Int. J. Rapid Manufacturing, Vol. 1, No. 1, 2009.

3. Mahapatra S S, Patnaik Amar (2006) Optimization of wire electrical discharge

machining (WEDM) process parameters using Taguchi method. International

Journal of Advanced Manufacturing Technology.

4. Hatala Michal Faculty of Manufacturing Technologies of the Technical

University of Košice Štúrova The Principle of Plasma Cutting Technology

and Six Fold Plasma Cutting.

5th International Multidisciplinary Conference.

5. Mahapatra S S (2007) An evolutionary approach to parameter optimisation of

submerged arc welding in the hard facing process 462 Int. J. Manufacturing

Research, Vol. 2, No. 4, 2007 .

6. Uttarwar S S, Chopade I K, Effect Of Voltage Variation On MRR For

Stainless Steel EN Series 58A (AISI 302B) In Electrochemical Machining: A

Practical Approach. 2OHProceedings of the World Congress on Engineering.

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