‫‪Difference between laser cutting and plasma cutting.

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‫‪Difference between 3 axis,4 axis and 5 axis milling.‬‬
‫‪EDM machine.‬‬

‫آيه أشرف فاروق إبراهيم‬

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 Difference between laser cutting and plasma cutting

Laser cutting •
Laser cutting is a technology, which enables a laser to cut of various
materials using the high-point of the cutting jet by the introduction of
energy and technical gas of high purity. Laser radiation is
characteristic, and thus practically unattainable by other methods. Gets
plenty of power here in the choice, but a very narrow area of the
spectrum. Its characteristics include consistent in time and space
radiation, and the most polarized beam with low divergence.Depending
on the cutting device is carried out in three ways: by burning, melting
or sublimation.Creation of the laser beam generally involves stimulating
a lasing material by electrical discharges or lamps within a closed
container. The beam is reflected internally through a partial mirror,
until it achieves sufficient energy to escape as monochromatic coherent
light. Generally, the narrowest part of the focused is less than 0.32 mm
in diameter. Of course, taking into account the thickness of the material,
the width of the gap as small as 0.10 mm are possible.
Plasma cutting •
Plasma cutting is basically a process that is used to cut generally steel
and sometimes other metals of different thicknesses. This process
consists of metal melting, and then disposing of the cut metal from the
slot. This is done by means of a concentrated plasma arc, having a large
kinetic energy. In fact, plasma cutting uses a high temperature that
prevails in the core plasma arc and high speed plasma stream. The

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electric arc is formed between the tungsten electrode and the cut object.
Principles of its formation is as follows: by passing the gas stream in the
compressed form of the arc for the phenomenon is a result of ionization
and high power density is possible to produce a stream of plasma. The
most commonly used gas plasma cutting is air and also in high-power
devices used argon, nitrogen, hydrogen, carbon dioxide. Plasma arcs are
C. Due to the high ° extremely hot and are in the range of 25 000
temperature plasma cutting edge of a destructive influence on the
confluence. This method we can usually cut from 50 mm to 150 mm
thick. This is a large range of metal cutting.

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Plasma cutting and laser cutting are two different methods of cutting
materials. Plasma cutting is a process that uses a high-velocity stream of
ionized gas to cut through electrically conductive materials such as steel,
aluminum, brass, and copper. Laser cutting is a process that uses a
focused beam of high-energy light to cut through materials such as
wood, plastic, and metal.
The main difference between plasma and laser cutting is the type of
energy used to cut the material. Plasma cutting uses an ionized gas
(plasma) to cut through electrically conductive materials while laser
cutting uses a focused beam of high-energy light to cut through non-
conductive materials. Plasma cutting is faster than laser cutting but is
limited to electrically conductive materials. Laser cutting can be used on
a wider range of materials but is slower than plasma cutting.

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 Difference between 3 axis,4 axis and 5 axis milling

3-axis machining •
After the operator enters milling instructions into a computer, the 3-
axis CNC machine will automatically complete the task by using a tool
to cut along three axes — X, Y, and Z, or left-to-right, front-to-back,
and up-and-down. Both CNC milling and CNC turning fall under the
umbrella of 3-axis machining. However, they function slightly
differently.
When using a 3-axis CNC milling machine, the material block remains
fixed in a vice or on a machine bed. Rotating drills or cutting tools are
connected to a spindle and move along the X, Y, and Z axes, removing
shavings to accurately form the final component. 3-axis CNC milling
machines are excellent for producing most geometries and simple parts.
By contrast, in the CNC turning process, the workpiece is attached to a
rotating spindle, and a lathe shapes the component. As the spindle
holding the workpiece rotates, a center drill or cutting tool traces the
component’s outer and inner perimeters or creates holes along the
center axis. Compared to CNC milling machines, CNC lathe turning
machines produce parts faster and offer cheaper per-unit costs, which is
advantageous for high-volume production runs.
Since a 3-axis CNC machine can only cut along three axes, it may
struggle with non-conventional shapes or designs with deep, narrow
cavities that are difficult to reach. When processing parts with complex
geometries, operators may have to manually reposition the workpiece,

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which can slow down the processing speed, raise labor and machining
expenses, and result in a less-than-perfect finished product.

4-axis machining •
This adds a rotation about the X-axis, called the A-axis. The spindle has
3 linear axes of movement (X-Y-Z), like in 3-axis machining, plus the A-
axis occurs by rotation of the workpiece. There are a few different
arrangements for 4 axis machines, but typically they are of the ‘vertical
machining’ type, where the spindle rotates about the Z axis. The
workpiece is mounted in the X-axis and can rotate with the fixture in
the A-axis. For a single fixture setup, 4 sides of the part
can be machined.
axis machining can be used as a more economically viable way of -4
machining parts theoretically possible on a 3-axis machine. As an
example, for a part we recently machined we found that using a 3-axis
machine would have required two unique fixtures at a cost of £1000 and
£800 respectively. By utilising the A-axis capability of 4-axis machining,
only one fixture was required at a cost of £1000. This also eliminated the
need for fixture change-overs, reducing costs even further. Eliminating
the risk of human error meant we machined the part to a high quality
with no need for expensive Quality Assurance investigations. Removing
the need to change fixtures has the additional benefit that tighter
tolerances can be held between features on different sides of the part.
Loss of accuracy due to fixturing and re-setup has been removed.
There are two types of 4-axis CNC machining: indexing and continuous.

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Index 4-axis CNC machining is when the 4th axis (A-axis) rotates whilst
the machine is not cutting material. Once the correct rotation is
selected, a brake is applied and the machine resumes cutting.
In continuous 4-axis machining, the machine can cut material at the
same time as the A-axis rotation, simultaneously. This allows complex
arcs to be machined, such as the profile of cam lobes, and helixes.
4-axis machining gives us the ability to machine angled features,
otherwise not possible with a 3-axis machine. Bear in mind that 4-axis
machining allows a single axis of rotation per fixture setup, so all angled
features must be angled about the same axes, or additional
fixtures put in place.

5-axis machining •
5-axis machines rely on a tool that moves In five different directions X,
Y, and Z, as well as A and B, around which the tool rotates. Using a 5-
axis CNC machine lets operators approach a part from all directions in
a single operation, eliminating the need to manually reposition the
workpiece between operations. 5-axis CNC machining saves time and is
ideal for creating complex and precise parts like those found In the
medical, oil and gas, and aerospace industries. There are a few different
kinds of 5-axis machines that product teams should be aware of,
including indexed 5-axis CNC machines, continuous 5-axis CNC
machines, and mill-turning CNC centers.
Like 3-axis CNC milling, the cutting tool only moves along three axes
and doesn’t maintain continuous contact with the workpiece in indexed
5-axis CNC machining. However, the machining table and tool head can

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automatically swivel in two directions between operations. Indexed 5-
axis machining is great for manufacturing housings, jigs, and fixtures. It
falls somewhere between 3-axis CNC milling and continuous 5-axis
CNC machining in terms of speed, precision, and the ability to handle
complex geometries.
In continuous 5-axis CNC machining, the cutting tool and the workpiece
can rotate and move simultaneously during operation, saving time and
allowing operators to manufacture intricate geometries with organic
surfaces. Continuous 5-axis CNC machining offers improved surface
finish, speed, and dimensional stability, but it has the highest cost-per-
parts ratio.
5-axis CNC machining
Turning mill CNC centers are practically identical to CNC turning
machines, with one exception — they’re equipped with CNC milling
equipment. The workpiece is attached to a spindle that can either rotate
or remain stationary while cutting tools remove material from it. By
combining the elements of CNC lathe machines with milling tools, mill-
turning CNC centers offer high levels of accuracy and geometric
versatility, making them great for creating parts with loose rotational
symmetries, such as camshafts or centrifugal compressors.
Not only do these types of 5-axis CNC milling machines offer greater
accuracy when machining deeper parts and hardened materials, but
they also offer higher yields and faster machining speeds. However, 5-
axis machining is more expensive due to the specialized equipment
necessary and the need for expert workers.

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The main difference between 3-axis and 5-axis milling machines is that
the workpiece can be worked on from three axes with the former and
five axes with the latter. Both are highly versatile, automated, and
replicable production processes that will enable you to quickly and cost-
effectively create accurate components. However, you may opt to use
one over the other for a variety of reasons.
If you’re on a budget or only need to cut a flat surface, 3-axis machines
might be the way to go. In addition to being more affordable than those
with five axes, 3-axis machines are simpler to program, so you won’t
have to Incur the cost of working with expensive expert programmers
and operators. Plus, prep time is shorter with 3-axis machining.

5-axis malling

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 EMD machine
EDM (electrical discharge machining) is a manufacturing process that uses
electrical sparks to erode metal parts. It is used to create intricate shapes and
features in hard metals such as steel, aluminum, brass, and titanium. EDM
machines use a combination of electrical current and dielectric fluid to erode
metal parts with precision and accuracy. The process works by sending an
electrical current through the dielectric fluid between two electrodes, one of
which is the workpiece. The current creates a spark that melts away tiny
particles of metal from the workpiece, forming the desired shape or feature.
EDM machines are used in a variety of industries including aerospace,
automotive, medical device manufacturing, and tool and die making. They
are also used for creating complex molds for injection molding processes.
EDM machines come in a variety of sizes and configurations depending on
the application they are being used for. Some common types include wire
EDM machines, sinker EDM machines, hole-drilling EDM machines, and
small hole-drilling EDM machines. Each type has its own advantages and
disadvantages depending on the application it is being used for.

EDM machine

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