In real production processes, 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, cutting section imperfections, dross accumulation, and cracks. These problems can arise from multiple factors, and even when oxygen purity is maintained at an optimal level and the equipment functions properly, several key elements can still lead to cutting quality issues. These factors mainly involve the torch, cutting nozzle, steel material quality, and the type of steel plate being used.
1. **Upper Edge Cutting Defects** – These are typically caused by excessive melting during the cutting process.
(1) **Edge Collapse**: The upper edge becomes rounded or melted due to overheating.
- **Causes**:
- Cutting speed is too slow, leading to over-preheating.
- The distance between the cutting tip and the workpiece is either too high or too low.
- Using a nozzle with a larger size than necessary, resulting in excess oxygen in the flame.
(2) **Droplet-like Melted Beads**: Small, droplet-shaped molten beads appear along the top edge of the cut.
- **Causes**:
- The steel plate surface is rusted or oxidized.
- The cutting nozzle is too close to the plate, causing intense preheating.
- The distance between the cutting tip and the plate is too large.
(3) **Eaves-like Edge Collapse**: A raised, uneven collapse forms along the upper edge of the cut.
- **Causes**:
- The preheating flame is too strong.
- The height between the cutting tip and the steel plate is too low.
- Cutting speed is too slow.
- Incorrect nozzle size or excessive oxygen in the flame.
These defects not only impact the aesthetics of the cut but also compromise the structural integrity of the material. To prevent such issues, regular maintenance of the cutting equipment, proper selection of nozzles, and consistent monitoring of gas purity and cutting parameters are essential. By understanding and addressing these common causes, manufacturers can improve the efficiency and quality of their flame cutting operations.
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