Cut quality issues for 1/2"

[Clayton]

So let me preface this by saying that I am new to CNC plasma cutting and everything I know is from experimenting with machine settings, online research, or by calling support for the table or my consumables supplier. So go easy on me.
I have a Hypertherm Powermax1650 (purchased used) on a Tracker 5x10 ProTable (also purchased used). I purchased 6760 to clean up my air and installed the filter inline just before the Plasma cutter connection. I am using genuine Hypertherm consumables: 220047 Shield, 220011 Nozzle, 220037 Electrode, and 220051 Swirl Ring (All 100 amp). I have been cutting lots of 14g and 10g parts for our shop with no issues (around 40A @ 125 IPM; .25 initial pierce height, 1sec pierce delay, and no THC because it doesn't seem to be working properly.) I reached these setting through lots of trial and error and many, many failed parts.

So I got a bid for some 1/2" parts and had never done anything that thick before, so I went and got some 1/2" scrap, threw it on the table after drawing the parts up in ACAD, and tried some cuts.

These were the best ones after a few adjustments. I ended up at 100A @ 18 IPM, 2sec pierce delay, .25 pierce height, and still no THC. My issue is the angle of the cut. I'm willing to make further adjustments and try again, but I wasn't really sure what to adjust. What do you guys think?

[Thor]

at 100 amps you are moving way too slow. I cut 1/2" at 65 amps and 30 ipm. .180" pierce ht, .060" cut ht on my PM85.

[Clayton]

I used your settings with a 2 second pierce delay and got this result.

Is there something else going on that I am missing here?

[jimcolt]

Use the 60 amp shielded consumables....open your manual to the 60 amp shielded cut chart for steel.....make sure all of the torch parts match the part numbers at the top of the cut chart. Set pierce height, cut height, pierce delay time and cut speed exactly as the cut chart recommends for 60 amp cutting of 1/2" steel. Good cuts will be the result. If for some reason the specs in the operators manual do not work....post the results here and we will help you troubleshoot this some more. The specs in the Hypertherm operators manual are correct....if you cannot achieve them....then we will find the problem so you can.

From the wildly varying angularity in your pictures......you are cutting with a severely damaged nozzle and / or shield. The nozzle and shield are damaged by piercing too close, piercing with inadequate pierce delay time.

For best cut quality with any plasma cutter....always use the consumables and power level that are lowest rated for the material and thickness being cut. You can cut 1/2" with 60, 80 or 100 amps...the best cuts will be at 60.

Jim Colt Hypertherm

[jimcolt]

In case you do not have the operators manual....you can download it at http://www.hypertherm.com . Here is the 60 amp cut chart for reference This is from a 1250 manual, same specs for the 1650), and the picture attached is a Powermax cut on 1/2" steel at book specs....holes were done with the plasma as well.

Jim Colt Hypertherm

IMG_2948.jpg (51.09 KiB) Viewed 1530 times

IMG_2948.jpg (51.09 KiB) Viewed 1530 times

[Jefferyea]

Wondering what is the best quality of cut in the half acre realm?

Thanks

[Nacs Fab]

Looks like the Steel is awful scaly on top/bottom. I would hit that with a DA or at minimum wire brush it.

[Clayton]

I talked to a local plasma cutting/welding supplier and he thought the signs pointed towards the torch lead and head. I was considering the Duramax torch upgrade anyway so I pulled the trigger. My cuts look like this now (no clean-up):

It seemed to make a big difference. I can now use the cut charts that came with the new torch pretty successfully, when before I had to slow the head down by 25% or more from the recommended speed. Based on the above picture does anyone have any further suggestions to improve my cut quality?

[Nacs Fab]

The Duramax Torch is one hell of an upgrade for the older machines. Well worth the money spent!