• Plasma Cutting is a process that uses a high-energy plasma arc to cut through a wide range of conductive materials (metals), such as steel, aluminum, and copper. The plasma cutting process is controlled by a computer program, which allows for precise cutting of a wide variety of shapes and sizes.

• The process of CNC plasma cutting starts by creating an electrical arc between an electrode and the material to be cut. This arc ionizes a gas, such as air or nitrogen, and creates a high-energy plasma stream. The plasma stream is directed through a constriction nozzle and directed at the material to be cut. The high-energy plasma stream melts the material, and a high-pressure gas (such as compressed air) is used to blow the molten material away from the cut edge, creating a clean and precise cut.

• The main advantage of CNC plasma cutting is its ability to cut through a wide range of conductive materials, including thick materials, with high speed and precision. It is also relatively low cost compared to other cutting methods. Additionally, CNC plasma cutting is able to cut complex shapes and bevel cuts with ease.

• On the other hand, CNC plasma cutting has some disadvantages as well. One of the main disadvantages is that the process generates high levels of heat and noise, which can be a hazard to operators. Additionally, CNC plasma cutting is not suitable for cutting non-conductive materials, and it's also not suitable for precision cuts on thin materials.

• Another limitation of CNC plasma cutting is that it can cause a "heat affected zone" (HAZ) that can cause a distortion of the cut material and make it more brittle. It's also not suitable for cutting materials that are sensitive to heat such as some plastics, wood, and some alloys.

Plasma Safety

• The workflow for designing and cutting parts using a CNC plasma cutter typically involves the following steps:

  • Design: The first step is to design the part using a CAD (computer-aided design) software. The design should take into account the material properties, thickness, and any specific requirements for the part.

  • Nesting: Once the design is complete, the next step is to arrange the parts on the material in an efficient way, this process is called nesting. Nesting software is used to optimize the use of the material and reduce waste.

  • Generating the G-code: The next step is to convert the design into machine-readable code, called G-code. This is done using a CAM (computer-aided manufacturing) software. The G-code is a set of instructions that the CNC machine will use to cut the parts.

  • Loading the program: The G-code is loaded into the CNC plasma cutter's controller and the material is loaded on the machine's table.

  • Setting up the machine: Before starting the cutting process, the machine needs to be set up properly. This includes setting the correct torch height, amperage, and cutting speed.

  • Cutting: The CNC plasma cutter follows the instructions in the G-code to cut the parts from the material. The operator monitors the cutting process and makes any necessary adjustments.

  • Finishing: After the cutting process is complete, the parts may need to be finished, such as deburring or cleaning the edges.

  • Inspecting the parts: Finally, the parts are inspected to ensure that they meet the design specifications and are free from defects.

• It's worth noting that the workflow may vary depending on the specific requirements of the parts and the equipment being used. Additionally, there may be additional steps such as material preparation, clamping and fixturing, and maintaining the equipment that are necessary for the specific process.

Answer the following prompts/questions in your own words - apply your personal experiences and opinions to the topics covered in this sub-module. Feel free to use multi-media visuals, references, etc.:

1. What is Plasma Cutting?

2. How does Plasma Cutting work?

3. A) What safety considerations are specific to plasma cutting?

B) What specific PPE should be worn when operating plasma cutters?

4. What workflow steps are specific to plasma cutting, and why?