Table of Contents

1.0 TITLE .................................................................................................................................. 3

2.0 OBJECTIVES ...................................................................................................................... 3

3.0 INTRODUCTION ............................................................................................................... 4

3.1 Theory .............................................................................................................................. 4

4.0 APPARATUS ...................................................................................................................... 5

4.1 Industrial Apparatus ......................................................................................................... 8

5.0 EXPERIMENTAL PROCEDURE ...................................................................................... 9

6.0 RESULT & DATA ANALYSIS ....................................................................................... 11

6.1 G Codes .......................................................................................................................... 12

6.2 Area Measurement of Final Product .............................................................................. 14

6.3 Sample of Calculation .................................................................................................... 15

7.0 DISCUSSION .................................................................................................................... 16

8.0 CONCLUSION .................................................................................................................. 17

9.0 RECOMMENDATION ..................................................................................................... 18

10.0 REFERENCES .................................................................................................................. 19

11.0 APPENDICES ................................................................................................................... 20

 Table of Figures

Figure 1: Plasma cutting works....................................................................................................... 4

Figure 2: Computer Display............................................................................................................ 5

Figure 3: Dassault System Catia Software...................................................................................... 5

Figure 4: FastCam Software ........................................................................................................... 5

Figure 5: Huawei CNC Plasma Machine ........................................................................................ 5

Figure 6: Plasma Cutter .................................................................................................................. 6

Figure 7: Inverter Air Plasma Machine .......................................................................................... 6

Figure 8: Gas Tank.......................................................................................................................... 6

Figure 9: PLACOM Digital Planimeter .......................................................................................... 7

Figure 10: Grinding Machine.......................................................................................................... 7

Figure 11: Alpha 1530E CNC plasma cutter .................................................................................. 8

Figure 12: Baileigh PT-44VH CNC Plasma Cutting Table ............................................................ 8

Figure 13: Hornet LT CNC Plasma Cutter ..................................................................................... 8

Figure 14: Final Product ............................................................................................................... 11

Figure 15: Area of the surface by using Measure Inertia in Catia ................................................ 14
1.0 TITLE
ADVANCE MANUFACTURING (CNC Plasma)

2.0 OBJECTIVES

1. To identify and understand the main operation of a CNC machine.

2. To study how to use the machine to produce the product through the CNC process.

3. To identify the types and causes defects in plasma cutting.

4. To be able to use the computer programming to set up the product and subsequently

generate through CNC machine.

3.0 INTRODUCTION
The numerical control (NC) is defined as programmable automation that the process is controlled
by the commands programmed for the operation of the machines. In CNC systems, the design is
highly automated for the mechanical part and its production program. CNC machining is a process
used in industries that use computers to control the production of machine tools. The dimensions
of the mechanical part are defined using the CAD software and then transferred to the production
directives using CAM software (computer aided manufacturing).

3.1 Theory

The plasma cutting process is a process that cuts materials by creating an electrical overheating
channel that produces hot plasma. The plasma is blown through a nozzle into the material at high
speed

When the electricity of the cutting torch moves along the plasma, it provides enough to melt the
piece. At the same time, high-speed plasma and compressed gas blow hot molten metal, thus
cutting the piece. Because plasma cutting produces a very hot cut that is easy to cut, it is useful
for cutting sheet metal with a curved or angled design.

Figure 1: Plasma cutting works

The plasma cutter works by transmitting the electric arc through the gas that passes through the
nozzle. Then the temperature of the gas increases to the plasma state. Since the workpiece is a part
of the circuit, the electrical conductivity of the plasma causes the arc to transfer to the workpiece.
4.0 APPARATUS
APPARATUS DESCRIPTION

 Used to display the drawing of the

product in 2D.

Figure 2: Computer Display

 It is used as a medium to draw the

shape of the product in 2D drawing.

Figure 3: Dassault System Catia Software

 It changes the Catia drawing to the

coding coordinate system so that the
CNC machine can detect the shape of
the product
Figure 4: FastCam Software

 It is used to transfer data to the plasma

cutter and control the movement of the
cutter.

Figure 5: Huawei CNC Plasma Machine

 APPARATUS DESCRIPTION

 It is used to cut the mild steel plate

according to the desired shape.

Figure 6: Plasma Cutter

 It is used to produce and supply

plasma for the cutting process.

Figure 7: Inverter Air Plasma Machine

 It is used to supply high pressure gas

that combine with the plasma when
cutting process is held.

Figure 8: Gas Tank

  It is used to trace and measure the area
of a 2D drawing.
 It consists of a tracer that equipped
with a magnifying glass which is
needed to trace drawing manually.
Figure 9: PLACOM Digital Planimeter

 It is used to grind the excessive metal

as a finishing of the product.

Figure 10: Grinding Machine

4.1 Industrial Apparatus

APPARATUS DESCRIPTION

 widely used in cutting stainless steel,

carbon steel and aluminum, one-off
job or repetitive jobs.
 The cutting speed is up to 6m/min.
 Uses drive rack and pinion to move
Figure 11: Alpha 1530E CNC plasma the cutter
cutter

 It includes a control podium and a

hand-held unit that has X, Y, and Z
jog controls.
 The table has an industrial down shaft,
water-based cooling and a ton of other
Figure 12: Baileigh PT-44VH CNC features.
Plasma Cutting Table
 The cutting size area limit is 4ft x 4ft.

 Advantages:
 Durable Performance.
 Powder coated metal surfaces.
 High Powered Flexibility.
 Easy-to-operate software
control
Figure 13: Hornet LT CNC Plasma Cutter
5.0 EXPERIMENTAL PROCEDURE

1) The design of the product is drawn in Catia software in 3D with the maximum size of
100mm X 100mm.

2) The design was change into drawing sheet. The drawing then saved in .dxf format.

3) The FastCam software then opened, click on “Files” and then click on “DFX Restore”
and button “Enter” was clicked.
4) Find the product design in .dxf format and then click the “Select” button. The design then
is saved in flash drive.
5) The flash drive that contain the product design is connected to the CNC plasma machine.
6) The coordinate coding system for the product design was transferred to the CNC plasma
machine to read.
7) Before cutting process is held, a test to trace the place where to cut the product was run.
8) When the test was finished, cutting process was started with the speed of 1500rpm.
9) The product then going to cooling process by flowing water onto the product.
10) The product was then went to finishing process after the cutting process is finished where
we need to grind the product to make it look good and perfect.

11) The product was sketched on a piece of paper and was brought to metrology laboratory to
calculate and measure the area of the product by using digital planimeter.

12) Recorded area is to differentiate the original area of the product and the cutting product
area.
6.0 RESULT & DATA ANALYSIS

3
1

Figure 14: Final Product

Number of Types of defects

defects
1 Edge dross

2 Overcut

3 Positive and negative cut angle

6.1 G Codes

G92 X0.Y0.
G21
G91
G00 X39.198 Y34.722
G41
M07
G01 Y5.
G03 I-7.071 J-7.071
G03 X-7.071 I-3.536 J-3.536
M08
G40
G00 X7.071 Y23.631
G41
M07
G01 Y5.
G03 I-7.071 J-7.071
G03 X-7.071 I-3.536 J-3.536
M08
G40
G00 X38.563 Y-24.922
G41
M07
G01 X3.535 Y3.535
G03 X-17.008 Y21.8 I-22.475 J0.
G01 Y-43.6
G03 X17.008 Y21.8 I-5.466 J21.8
G03 X-4.999 Y5. I-5. J0.
M08
G40
G00 X-70.234 Y-2.395
G41
M07
G02 X4.454 Y14.191 I33.135 J-2.605
M08
G40
G00 Y-33.592
G41
M07
G02 Y33.592 I28.682 J16.796
G02 X28.681 Y13.204 I11.871 J11.966
G02 Y-60. I16. J-30.
G02 X-28.681 Y13.204 I-16.81 J1.238
G02 X-4.454 Y14.191 I28.682 J16.796
M08
G40
M02
6.2 Area Measurement of Final Product

Experimental Value

Shape outline Left Eye Right Eye Mouth Total area

(cm²) (cm²) (cm²) (cm²) (cm²)
57.8 2.80 2.80 4.30 47.9
58.0 2.79 2.77 4.42 48.02
57.9 2.89 2.87 4.25 47.89
57.8 2.84 2.78 4.32 47.86
Average 47.92

Theoretical Value

Figure 15: Area of the surface by using Measure Inertia in Catia

Total area = 44.12 cm²

6.3 Sample of Calculation

Average value for surface area

47.9 + 48.02 + 47.89 + 47.86

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 =
4

= 47.92 𝑐𝑚2

Percentage of error

𝐸𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 𝑣𝑎𝑙𝑢𝑒 − 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑣𝑎𝑙𝑢𝑒

𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 = | | × 100%
𝐸𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 𝑣𝑎𝑙𝑢𝑒

47.92 cm2 − 44.12 cm2

= × 100%
47.92 cm2

= 7.93 %
7.0 DISCUSSION

From the experiment we can see defects that are present on the final product. Firstly, we have
edge dross on the left of the product. This happens because of the CNC machine need to reduce its
speed when making acute direction change like right angle. Thickness of the steel plate, the speed
of cutting, its ampere also the material composition effects the defects. This is one of the defects
that hard to be prevented as it may be reduced by correcting the drawing before cutting.

Not just that, on the right top eye side there is overcut. Overcut happens when the CNC machine
cut more than it should be cut. In a way which it couldn’t be doing that but as a machine it may
sometimes have it flaws. Maybe the presets on the machine that caused it to act like that. Other
effects maybe the steel plate surface is unsmooth and cause it to effect while cutting.

Lastly, some positive and negative cut angle are present on the product. Negative cut angle is when
it is smaller which goes undercutting while positive angle when the sample is smaller than bottom.
The negative level is caused by slow cutting speed, less torch standoff and high ampere. For
positive angle, it may be caused by low amperage, too high torch standoff and shabby nozzle. All
the defects caused the product to become imperfect and can be discusses.

The area is then calculated and been compared with the theory. The area of the product is 47.92cm2
which is bigger than its theoretical area in the Catiya which is 44.12cm2. Then the percentage error
of the area was calculated and got 7.93%. This number shows that the experiment is a quite success
as it shows just a little percentage error.
8.0 CONCLUSION

This experiment was a complete success, the conclusion is that we can finally achieved the
objectives of the experiment. We get a new knowledge on CNC plasma cutting from its preparation
process and its cutting stage. We can able to know the types of defects that happens on the product
after the experiment. Our products give less defects as the percentage error compared to the
theoretical area is less which is less than 10%.

CNC plasma cutting is one of the advance machinery that can be used for all engineers and students
for easier the works in manufacturing and industries in the future.
9.0 RECOMMENDATION

 Calibrate the machine so the presents are not faulty.

 Check its torching power before start cutting.

 Smoothen the surface before cutting to avoid overcut.

 Check the ampere as it could affect the cutting.

 Use suitable metal for the process

10.0 REFERENCES

Website
1. Casting Defects. Retrieved from
https://www.slideshare.net/BhanuChandar4/casting-procedure-defects

2. Industrial plasma cutting. Retrieved from

http://plasmacuttersreviews.com/cnc-plasma-table-reviews/

3. Industrial plasma cutting. Retrieved from

https://hornetcs.com/hornet-lt-cnc-plasma-cutter/

4. Plasma cutter mechanism. Retrieved from

https://torchmate.com/white-papers/How-a-plasma-cutter-works

5. Operation of CNC plasma cutting. Retrieved from

https://www.researchgate.net/figure/Parameters-of-CNC-plasma-cutting-machine-
operation_fig5_291336407

6. Numerical Control. Retrieved from

https://en.wikipedia.org/wiki/Numerical_control

7. CNC machine. Retrieved from

https://www.thomasnet.com/about/cnc-machining-45330503.html

8. CNC machine operation. Retrieved from

https://www.brighthubengineering.com/manufacturing-technology/55787-what-is-the-
cnc-machine-how-cnc-machine-works/

9. CNC milling overview. Retrieved from

https://astromachineworks.com/what-is-cnc-machining/

Journal
1. Serope Kalpakjian & Steven R. Schmid, Manufacturing Processes for Engineering
Materials, 4th Edition, Illinois Institute Of Technology, Prentice Hall, 2003.
11.0 APPENDICES