In real-world production, CNC flame cutting machines often encounter various quality issues, which can significantly affect the final product's appearance and structural integrity. Common defects include edge irregularities, uneven cut sections, slag accumulation, and cracks. These problems can arise from multiple factors. If oxygen purity is maintained at a standard level and the equipment is functioning properly, the main causes of flame cutting defects typically stem from several key areas: the torch, the cutting nozzle, the material quality of the steel plate, and the type of metal being used.
1. **Edge Cutting Quality Defects** – These are usually caused by excessive melting during the cutting process.
(1) **Upper Edge Collapse**: The top edge of the cut becomes rounded or collapsed due to rapid melting.
- **Reasons**:
- Cutting speed is too slow, leading to excessive heat buildup.
- The distance between the cutting tip and the workpiece is either too high or too low.
- A larger nozzle size is used, resulting in excess oxygen in the flame.
(2) **Droplet-Like Melted Bead Formation**: This occurs when small, droplet-shaped melted beads appear along the upper edge of the cut.
- **Reasons**:
- The steel surface is rusted or oxidized.
- The cutting nozzle is too close to the steel plate, causing intense preheating.
- The height between the cutting tip and the steel plate is too high, leading to uneven heat distribution.
(3) **Eaves-Like Collapse on the Upper Edge**: A convex, eaves-like deformation appears on the top edge of the cut.
- **Reasons**:
- The preheating flame is too strong.
- The cutting tip is positioned too close to the steel plate.
- The cutting speed is too slow.
- The height between the cutting tip and the workpiece is inconsistent, and an oversized nozzle is used with excessive oxygen.
To ensure consistent and high-quality cuts, operators must carefully monitor and adjust parameters such as cutting speed, nozzle height, oxygen pressure, and nozzle size. Additionally, regular maintenance of the machine and proper inspection of the steel material before cutting can help prevent many of these common defects. By understanding and addressing the root causes of these issues, manufacturers can improve efficiency, reduce waste, and enhance overall product quality.
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