Mechanized cutting is an essential process that makes manufacturing possible in our industrial world. Now, as with any other process, there are plenty of ways to perform it. In this article we are going to discuss mechanized cutting, highlighting some of the most used equipment used to achieve the perfect cut. Let’s start with the basic concept.
What is mechanized cutting?
When it comes to metalworking, mechanized cutting refers to the processes that incorporate machinery or equipment to mechanize and enhance the efficiency of cutting operations. The idea is to cut metals in a precise and repeatable manner. It is a widely used process in many industries, including manufacturing, construction, and mining.
Mechanized cutting processes
There are a variety of mechanized cutting processes available, including:
Plasma cutting: This uses a plasma arc to cut metal and other materials. Plasma arcs are very hot and can cut through a variety of materials, including steel, stainless steel, aluminum, and titanium.
Laser cutting: This uses a laser beam to cut metal and other materials. Laser beams are very precise and can cut through a variety of materials, including steel, stainless steel, aluminum, and plastics.
Waterjet cutting: This uses a high-pressure jet of water to cut metal and other materials. Waterjet cutting can cut through a variety of materials, including steel, stainless steel, aluminum, and stone.
Oxyfuel cutting: This uses a flame to cut metal and other materials. Oxyfuel cutting is typically used to cut steel and other ferrous metals.
Mechanized Sawing: Machines like chop saws, band saws, or radial arm saws are automated for repetitive cutting motions.
Mechanized Shearing: Power shears, powered by hydraulics, automate the shearing of metal plates or bars.
Mechanized Drilling: Drill heads on mounts move automatically to drill holes in pre-programmed patterns. Useful for holes off the CNC centerline.
Advantages and disadvantages of mechanized cutting
If you ask any engineer whether they would go back to the time when everything was manual, you are going to receive a clear no for an answer. Evidently, there are more advantages than disadvantages when it comes to mechanized cutting. Nevertheless, we are going to mention all of them here.
Advantages of mechanized cutting
Increased productivity: Significantly increases the productivity of cutting operations. This is because mechanized cutting equipment can operate at much faster speeds than manual cutting tools.
Improved cut quality: Programmed machines make precise, repeatable cuts. They can produce more consistent and reproducible cuts than manual cutting. This is because mechanized cutting equipment is typically computer-controlled, which ensures that the cutting parameters are maintained precisely.
Reduced operator fatigue: Eliminates the need for manual operation, which can reduce operator fatigue and improve safety.
Improved safety: Improve safety by reducing the operator’s exposure to hazards associated with cutting, such as sharp edges, heat, and noise. It minimizes exertion and exposure to blade hazards.
Reduced costs: Help to reduce costs in the long term by improving productivity and reducing waste. Faster cycles and less rework provide cost savings over manual methods.
Flexible: CNC programming allows customizing cutting patterns easily.
Reduced waste: Optimized cutting patterns and machine precision reduce material waste.
Disadvantages of mechanized cutting
High initial investment cost: The equipment can be expensive to purchase, install, and maintain.
Requires skilled operators: The equipment requires skilled operators to program and operate the equipment safely and efficiently.
Maintenance: Preventative maintenance required on servos, controllers, hydraulics, etc.
Limited flexibility: Mechanized cutting equipment is often designed for specific applications, which can limit its flexibility. Also, weight and size of materials must fit machinery capabilities.
Safety concerns: Mechanized cutting equipment can be dangerous if not operated properly.
Common applications of mechanized cutting
Mechanized cutting is a versatile process that can be used to cut a wide variety of metals, including steel, stainless steel, aluminum, etc. It is used in a wide variety of industries, like:
Metal fabrication: Plasma, laser, and waterjet cut parts from plate, tube, sheet, and structural shapes. Commonly cut carbon steel, aluminum, stainless steel, etc.
Automotive: Laser and plasma cut body panels, frames, and components from sheet metal in high volume.
Aerospace: Precise laser and waterjet cutting of titanium and aluminum aircraft structural parts.
Shipbuilding: Plasma cutting shapes large steel plates and components for ship hulls and superstructures.
Construction: Plasma cutting structural steel shapes like I-beams, channels, and angles to be used in bridges, roads, and highways
Piping: Orbital cutting machines slice pipes for accurate prefabricated piping spools and installations.
Sculpting: CNC plasma and waterjet create metal artwork and sculptures from sheet and plate stock.
Equipment for mechanized cutting: Cutting carriages
Cutting carriages are mobile devices that are used to guide and support a cutting torch or laser beam along the cutting path. They are typically used for mechanized cutting, which is a process in which the cutting parameters are controlled mechanically or electronically.
This equipment can be used to cut a variety of metals, including steel, stainless steel, aluminum, and others. They can also be used to cut a variety of joint types, including straight cuts, bevel cuts, and hole cuts. These are valuable tools for improving productivity, quality, and safety in a wide variety of industries. They are key technology equipment in many modern manufacturing and construction processes.
Features of cutting carriages
Cutting carriages are mechanized tools used to carry out automated cutting on large cylindrical parts like pipes, tanks, and vessel shells. Their mechanized operation enhances efficiency and cut consistency compared to manual methods. Key features of cutting carriages include:
- Mounting: The compact carriage frame mounts around the cylinder at the desired cut location
- Propulsion: An internal drive system propels the carriage along the axis of the cylinder as cutting is performed
- Cutting tool: Typically, an oxy-fuel or plasma torch provides the cutting power. May include multiple cutting heads
- Tool manipulation: Arms pivot and guide the cutting tip to maintain proper angles against the workpiece
- Speed control: Cutting speed is optimized to provide desired cut quality and progress rate
- Tracking: Guide wheels or magnetic tracks keep the carriage aligned axially during travel
- Controls: Programmable controls automate torch functions like arc voltage, gas flow, and on/off
- Portability: Lightweight designs allow movement between job sites
- Safety: Proper guarding prevents contact with moving parts during automated operation.
How to use a cutting carriage
To use a cutting carriage for mechanized cutting, the following basic steps should be followed:
- Use the correct cutting carriage for the application. There are a variety of cutting carriages available, so it is important to select one that is compatible with the cutting machine and the materials being cut
- Position properly the cutting carriage. The cutting carriage should be positioned in a way that the cutting torch or laser beam is aligned with the cutting path
- Set the cutting parameters correctly. The cutting parameters, such as the cutting speed, power, and gas flow, should be set according to the cutting process and the materials being cut
- Monitor the cutting process. The cutting process should be monitored to ensure that the cut is being made properly
- Stop if needed. Stop the cutting process immediately if any problems are observed.
Benefits of cutting carriages
Here are some of the benefits of using cutting carriages for mechanized cutting:
Increased productivity: Can significantly increase the productivity of cutting operations by automating the cutting process.
Improved cut quality: Can produce more consistent and reproducible cuts than manual cutting.
Reduced operator fatigue: They eliminate the need for manual operation, which can reduce operator fatigue and improve safety.
Improved safety: Can help to improve safety by reducing the operator’s exposure to hazards associated with cutting, such as sharp edges, heat, and noise.
Equipment for mechanized cutting: Cutting tables
Cutting tables are used to hold and support the material being cut during mechanized cutting. They are typically made of a sturdy material, such as steel or aluminum, and have a flat surface that allows the cutting torch or laser beam to move smoothly along the cutting path.
They come in a variety of sizes and configurations to accommodate different types of materials and cutting processes. Some cutting tables are designed for specific applications, such as cutting sheet metal or pipes. Others are more general-purpose and can be used to cut a variety of metals.
Cutting tables provide a robust, programmable work platform ideal for precision, automated cutting of sheet stock and plate material. They are an essential piece of equipment for almost every mechanized cutting operation. They help to improve safety, cut quality, setup time, and productivity.
When we refer to the metal structure where the cutting takes place, we call it cutting table. But if you want to refer to the whole package, which is the structure, the plasma or laser power source, the torches and all its accessories, we call that a cutting system.
Features of cutting tables
Cutting tables are a key piece of equipment used for mechanized cutting operations. Some main features of cutting tables include:
Flat work surface: Provides stable and level support for sheet stock during cutting. Often made of gridded or honeycomb steel.
Moving gantry: The gantry mounted perpendicular to the table houses the cutting tool and traverses the work area.
Cutting tool mounts: Cutting tools like plasma, laser, waterjet or router heads are mounted to the gantry via motorized articulation rails.
Workpiece securing: Clamps, vises, or vacuum hold-downs secure material firmly to the table during cutting.
Programmable control: Computer numeric control (CNC) coordinates gantry motion and cutting tool functions.
Precision guides: The gantry glides along the table on linear rails, bearing blocks, or drive screws for smooth, precise travel.
Fume extraction: Integrated ventilation captures dust and fumes generated near the cutting surface.
Material handling: Roller tables, conveyors, or rotary tables manage material flow to and from the cutting table.
Benefits of cutting tables
Here are some of the benefits of using cutting tables for mechanized cutting:
Increased safety: Help to protect the operator from hazards associated with cutting, such as sharp edges, heat, and sparks.
Improved cut quality: Provide a stable platform for the cutting torch or laser beam to move along, which can help to improve cut quality.
Reduced setup time: Can help to reduce setup time by providing a pre-aligned surface for the material to be placed on.
Increased productivity: Can help to increase productivity by eliminating the need for the operator to manually position and support the material during cutting.
Equipment for mechanized cutting: Orbital cutting
Orbital cutting is a type of mechanized cutting that uses a rotating cutting head to create a circumferential cut around a joint. It is a precise and repeatable process that can be used to produce high-quality cuts in a variety of metals, including steel, stainless steel, aluminum, and titanium.
These systems are available in a variety of sizes and configurations to accommodate different types of materials and cutting applications. The degree of automation varies greatly as well.
Types of orbital cutting equipment
Orbital cutting refers to mechanized cutting equipment where a cutting torch or saw rotates around a fixed pipe or cylindrical vessel to make a circumferential cut. Mechanized orbital cutting achieves quality and precision cuts with minimal setup time compared to manual rotary cutting methods. Some equipment used for orbital cutting includes:
Orbital cutting machines: Enclosed track with rotating torch carriage makes precision pipe and tube cuts. Programmable with built-in controls.
Pipe bevelers: Rotating cutter heads machine angled bevel cuts on pipe ends for welding joint preparation.
Cutting buggies: Compact cutting torch carriages propel along and rotate around large tanks and vessels to cut shell rings.
Pipe cutting tables: Rotary tables with clamping fixtures accurately rotate pipe specimens for defined cutting patterns.
Portable orbitals: Lightweight and compact orbital cutters that mount directly to pipe for in-place cuts. Ideal for pharma and food production plants.
Dual torch machines: Some orbital cutting machines utilize two plasma or oxy-fuel torches for faster cuts.
CNC controls: Programmable motion controls coordinate rotational and linear movements for the cut pattern. The degree of automation varies between brands and even models.
Guide tracks: Cam, wheel, or magnet guidance ensures the carriage stays centered on the axial path. These accessories are essential for orbital cutting.
Benefits of orbital cutting
Orbital cutting is a valuable tool for improving the quality and productivity of cutting operations in a variety of industries, including aerospace, automotive, electronics, and medical devices. Here are some of the benefits of using orbital cutting for mechanized cutting:
High precision: They can produce very precise cuts, with tolerances of up to ±0.001 inches.
Repeatability: They are able to consistently produce high-quality cuts, even on complex or repetitive parts. Some equipment includes memory to store some cuts and perform it with pressing one button.
Versatility: Can be used to cut a variety of materials and shapes. Diameters vary greatly as well.
Automation: Orbital cutting systems can be automated or semi-automated to reduce operator fatigue and improve productivity.
Other equipment for mechanized cutting
The equipment needed for mechanized cutting will vary depending on the specific process and application. However, some of the most common equipment includes:
Abrasive waterjets: High pressure garnet abrasive and water focused through a nozzle that cuts intricate shapes in plate stock.
Plasma power source: The machine that generates the plasma beam to be used for cutting. For mechanized cutting Hypertherm has the models MAXPRO200, XPR170 and XPR300.
Shearing: Hydraulic powered shears provide forces for repetitive metal bar, plate, and sheet shearing.
Robotic arms: Robots that manipulate cutting tools like welding torches, routers, knives.
Drilling: Computer numeric controlled (CNC) drilling machines perform automated hole drilling patterns.
Saws: Mechanized chop saws, band saws, or radial arm saws make repetitive cuts actuated by machine controls.
Mechanized cutting: Last thoughts
Mechanized cutting is the use of machines and tools to cut materials in a precise and repeatable manner. It is a widely used process in many industries, including manufacturing, construction, and mining.
Most likely, if you are reading this article, either you have set in place some mechanized cutting operation, or you want to get started with it. In any case, count on us to guide you through. We have decades helping companies to start or improve mechanized cutting operations. Feel free to reach out to us at your earliest convenience.
