Chapter 1 : Company Profile

METALTEC PRODUCTS PVT. LTD. is a Plasma Cutting and Laser Cutting Company. The
Company is situated at GIDC-2,Mehsana,Gujarat. The main aim of the company is to take
orders from major companies for the cutting work and cut metal plates in desired plates using
CNC Plasma Cutting Machine and CNC Laser cutting Machines. The Company owns two
CNC Plasma Cutting Machines and one CNC Laser Cutting Machine imported from China.
The name of the CNC Laser Cutting Machine is FIBERBLADE 6025.
The Company takes orders from other manufacturing companies for desired shaped cutting
parts for their manufacturing purposes. The FIBERBLADE 6025 is the first and only one of
its kind in Mehsana city.

Chapter 2 : Internship Outline

I have spent most of my most of period of internship in learning operation of CNC Plasma
Cutting Machine and CNC Laser Cutting Machine.One drawback of my internship was that
that I was not allowed to touch or interfere with any of the machine in operating condition so
I could not get my hands-on experience on the machines.

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Chapter 3 : Plasma Cutting

3.1 Introduction :
Plasma cutting is a process that cuts through electrically conductive materials by
means of an accelerated jet of hot plasma.
Typical materials cut with a plasma torch including steel, Stainless
steel, aluminum, brass and copper.
Plasma cutting is often used in fabrication shops, automotive repair and restoration,
industrial construction, and salvage and scrapping operations.
Due to the high speed and precision cuts combined with low cost, plasma cutting sees
widespread use from large-scale industrial CNC applications down to small hobbyist
shops.

3.2 Process :
The basic plasma cutting process involves creating an
electrical channel of superheated, electrically ionized
gas i.e. plasma from the plasma cutter itself, through the
work piece to be cut, thus forming a completed electric
circuit back to the plasma cutter via a grounding clamp.
This is accomplished by a compressed gas (oxygen, air,
inert and others depending on material being cut) which
is blown through a focused nozzle at high speed toward
the work piece.
An electrical arc is then formed within the gas, between an electrode near or
integrated into the gas nozzle and the work piece itself. The electrical arc ionizes
some of the gas, thereby creating an electrically conductive channel of plasma.
As electricity from the cutter torch travels down this plasma it delivers sufficient heat
to melt through the work piece. At the same time, much of the high velocity plasma
and compressed gas blow the hot molten metal away, thereby separating i.e. cutting
through the work piece.

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 3.3 Advantages :
Cutting Speed Robotic plasma cutters are five times faster than traditional, manual
torches, and are able to cut up to 500 inches per minute.
Wide Range of Material and Thickness Plasma cutting robots can make precise
cuts in a variety of metals and thicknesses. These plasma cutters use nitrogen, which
enables them to cut steel, aluminum and other metals.
Ease of Use Robot plasma cutters require marginal training, making them user-
friendly.
Multi-tasking Robot plasma cutting systems are not just limited to cutting. They
can be used as gauges, lining up material perfectly.
Safety This cutting application uses gas that is not highly flammable, eliminating
some of the safety hazards with gas cutting procedures.
Economical Plasma cutting is a cost effective application it is less expensive than
laser or water-jet cutting.
Keeps Materials Cool Despite operating at high temperatures, plasma
cutting robotic systems can keep the surface of materials cool. This prevents warping
and damage to paint and other coatings.

Chapter 4 : CNC Plasma Cutting Machine

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 4.1 Introduction :
A CNC plasma system is a machine that carries a plasma torch, and can
move that torch in a path directed by a computer. The term CNC refers to
Computer Numerical Control, which means that a computer is used to direct
the machines motion based on numerical codes in a program.
CNC plasma machines usually use a different type of plasma system than
hand-held cutting applications, one specifically designed for mechanized
cutting instead of hand-held cutting.
Mechanized plasma systems use a straight barreled torch which can be carried
by a machine, and have some type of interface that can be controlled
automatically by the CNC.
There are some entry level machines that can carry a torch designed for hand-
held cutting,

4.2 CNC Plasma : Parts :

The CNC may be an actual controller designed for machine tools, with a
proprietary interface panel and a specially designed control console, such as a
Fanuc, Allen-Bradley, or Seimens controller. Or it could be as simple as a
Windows based laptop computer running a special software program and
communicating with the machine drives through the Ethernet port.
To cut parts from steel plate, the motion of the torch is controlled by the CNC.
A part program, usually just a text file with M-codes and G-codes,
describes the contours of the part and when to turn the torch on and off. Part
programs are usually created by a piece of software called a post-processor,
which can take a part geometry from a CAD file and translate it into M-codes
and G-codes that the CNC can read.
A CNC plasma machine also requires a drive system, consisting of drive
amplifiers, motors, encoders, and cables. There will be at least two motors,
one for the X-axis and one for the Y-axis. There is a drive amplifier for each
motor, which takes a low-power signal from the CNC and turns it into a
higher-powered signal to move the motor. Each axis has a feedback
mechanism, usually an encoder, which creates a digital signal indicating how
far the axis has moved. Cables take the power from the amplifier to the motor,
and carry the position signals from the encoder back to the CNC.
The CNC reads the part program and then outputs signals to the machines
drive system which moves the torch in the desired direction at the
programmed speed. The CNC reads the encoder feedback and makes
corrections to the drive signals as required to keep the torch motion on the
programmed path. All of the electronics in the CNC and drive system work
and communicate very quickly, often measuring and updating position
information every few milliseconds. This allows the machine motion to be
smooth and accurate enough to produce plasma cut parts with a smooth,
straight, consistent edge quality, and precise part dimensions.
Finally, a CNC plasma system will have some sort of I/O system, an
electrical system that handles Inputs and Outputs. This is how the CNC turns
on the plasma at the appropriate time, by turning on an output that closes a

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 relay, for example. The CNC uses inputs to know when the plasma arc has
started, and is ready to move. Those are the most basic Inputs and Outputs
required, but obviously there can be many more.

4.3 CNC Plasma Cutting Steps

1. Part Design :

The CNC Plasma Cutter requires

Part design file which is compatible
Controller of CNC Plasma Cutter.
For this purpose any CAD software
like AutoCAD is used to create part
design and saved as compatible
format to Controller

2. Table Setup :

Once your .dxf (or other file) is on a flash drive, plug this into the
computer that is connected to the plasma cutter. Open up the PlasmaCAM
software, initialize the machine, open your flash drive, and file --> import
your part. It should appear on the computer rendition of the table. Once
your machine is initialized and your sheet metal is in the right place, slide
your part around on the computer and check where your part is by moving
the machine to it. The machine tip should move on the computer and the
machine. Move your part on the table to where it has room and will be cut
all around it without interference or running into another hole in your
stock. Once you have your part positioned, you can cut.

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 3. Cut Setup :
To cut, make sure that the
torch has power, the
machine has power, and all
of the ventilation is
on. Once your part is in the
right place on the table,
highlight the part and
combine all of the separate
entities of the sketch. This
means that instead of a lot of
small lines holding your part
together, you have several continuous lines. The command for this on
PlasmaCAM is [Command + K]. Once you have everything joined
together, convert it to cut paths. When converting your lines to actual cut
paths, start from the inside entities and end with the outside contour. For
the inside cuts, select the center of the hole so it knows to start the cut
from the inside, and for the outside contour select from the outside so it
will cut from the outside.

4. Cutting and Removal :

Once you are ready to
cut, make sure the
machine is on, the area is
ventilated and the cutting
torch is powered
on. Once all of these are
good, you can cut out
your part. Make sure not
to look directly at the
torch because the
brightness on some
torches is similar to that
of a welder and may give
you welder's eye. Once your part is cut, move the machine head out of the
way, get a pliers and wiggle your part out of the hole. For the more
complex parts, you may need to wiggle the part a little more or hit it with a
mallet to loosen it from the sheet. Once you have it you can either let it
cool off or dunk it in water or oil if you want a quick cooling. With the
smiley face part, I was lucky enough that it dropped through onto the
floor. Once your part is cooled you can hammer off the slag and file or
grind the edges down for a smooth finish. Sandblasting will give it a nice
finish and take off the burn marks. Now you know how to make parts on a
plasma cutter! You can bend your parts or just use them how they are
flat. The possibilities are endless with a plasma cutter.

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Chapter 5 : Laser Cutting

5.2 Introduction :
Laser Cutting Process is the process of cutting material in desired shape using Laser
beam.
It uses computer to guide Laser throughout the cutting process to acquire desired
shape of material.
Laser Cutting is a non-contact process which utilizes a laser to cut materials, resulting
in high quality, dimensionally accurate cuts.
The process works by directing the laser beam through a nozzle to the workpiece.
A combination of heat and pressure creates the cutting action.
The material melts, burns, vaporizes, or is blown away by a jet of gas, leaving an edge
with a high-quality surface finish.

5.3 Working Principle :

The laser beam is a column of very high
intensity light, of a single wavelength, or
color. In the case of a typical CO2 laser, that
wavelength is in the Infra-Red part of the
light spectrum, so it is invisible to the human
eye. The beam is only about 3/4 of an inch in
diameter as it travels from the laser
resonator, which creates the beam, through
the machines beam path. It may be bounced
in different directions by a number of
mirrors, or beam benders, before it is
finally focused onto the plate. The focused

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 laser beam goes through the bore of a nozzle right before it hits the plate. Also
flowing through that nozzle bore is a compressed gas, such as Oxygen or Nitrogen.
Focusing the laser beam can be done by a special lens, or by a curved mirror, and this
takes place in the laser cutting head. The beam has to be precisely focused so that the
shape of the focus spot and the density of the energy in that spot are perfectly round
and consistent, and centered in the nozzle. By focusing the large beam down to a
single pinpoint, the heat density at that spot is extreme. Think about using a
magnifying glass to focus the suns rays onto a leaf, and how that can start a fire. Now
think about focusing 6 KWatts of energy into a single spot, and you can imagine how
hot that spot will get.
The high power density results in rapid heating, melting and partial or complete
vaporizing of the material. When cutting mild steel, the heat of the laser beam is
enough to start a typical oxy-fuel burning process, and the laser cutting gas will be
pure oxygen, just like an oxy-fuel torch. When cutting stainless steel or aluminum, the
laser beam simply melts the material, and high pressure nitrogen is used to blow the
molten metal out of the kerf.
On a CNC laser cutter, the laser cutting head is moved over the metal plate in the
shape of the desired part, thus cutting the part out of the plate. A capacitive height
control system maintains a very accurate distance between the end of the nozzle and
the plate that is being cut. This distance is important, because it determines where the
focal point is relative to the surface of the plate. Cut quality can be affected by raising
or lowering the focal point from just above the surface of the plate, at the surface, or
just below the surface.
There are many, many other parameters that affect cut quality as well, but when all
are controlled properly, laser cutting is a stable, reliable, and very accurate cutting
process.

5.4 Advantages :
Laser cutting is a manufacturing process which can eliminate the need for
machining on many engineering jobs, enabling you to save money on
manufacturing costs
Laser cutting presents certain advantages over plasma cutting as this process is
more precise and uses less energy when cutting steel and aluminium sheets.
The precision levels and edge quality achieved with laser cutting machines are
better than traditional cutting methods, as the laser beam will not wear during the
laser cutting process. Laser cutting technology also enables us to cut complex

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 shapes without the need for tooling and at a similar or faster speed than other
cutting methods.
Laser cutting also allows us to cut small diameter holes with complex detail and
good edge quality in either sheet, plate, tube or box section.

Chapter 6 : CNC Laser Cutting Machine

6.1 What is Laser Cutter?

There are a few different types of laser cutters, but they all essentially use the same
process of using a laser to cut material.
The laser originates from a laser resonator, which sends out a beam of intense light
through reflects through a system of mirrors to the cutting head.
Within the cutting head, the laser is focused through a lens and narrowed down to an
extremely thin, concentrated beam. This beam is projected down at the material and
can cut or raster the raw stock, which I'll cover in more detail later
The cutting head is usually mounted on what is called an XY gantry, which is a
mechanical system driven usually by belt or chain that allows for the precise
movement of cutting head within a given rectangular area, which is the size of the
work bed.
The gantry allows the laser head to move back and forth and forward and back over
the work piece so that it can make precise cuts anywhere on the bed. In order for the
laser to actually cut, the focal point of the lens, where the laser would be at its finest,
needs to be on the surface of the material it is cutting through. All laser cutters require
a focusing procedure before making their cuts to ensure that the laser cuts well.
The difference between different types of laser cutters comes from what types of
lasers the machines have. The type of laser defines what type and thickness of
material it can cut through, because different laser types have different power ranges.

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 Usually, higher power lasers are used on the industrial scale to cut out large sections
of sheet metal or plastics, while lower power lasers are used for a wide range of
thinner, more potentially flammable materials like paper and card stock, wood, and
some plastics. I'll cover the main types of laser cutters as well as the important
settings laser on.

6.2 Types of Laser Cutters :

1. CO2 Lasers: The laser is generated from electrically stimulated gas mixtures (mostly
comprising of carbon dioxide). CO2 lasers are the most common types of laser cutters
because they are low power, relatively inexpensive, efficient, and can both cut through and
raster a wide variety of materials.
Materials: wood, paper based products (cardboard, etc), leather, acrylic, glass, some plastics,
and some foams (can raster on anodized metals).

2. Neodymium Lasers: The laser is formed from neodymium doped crystals. These lasers
have a much smaller wavelength than CO2 lasers, meaning they have a much higher
intensity, and can thus cut through much thicker, stronger materials. However, because they
are so high power, parts of the machine wear and tend to need replacing.
Materials: metals, plastics, and some ceramics.

3. Fiber Lasers: These lasers are made from a "seed laser", and then amplified via special
glass fibers. The lasers have an intensity and wavelength similar to that of the neodymium
lasers, but because of the way they are built, they require less maintenance. These are mostly
used for laser marking processes.
Materials: metals and plastics.

6.3 Design Software for Laser Cutters :

A Laser cutter works very much like your everyday inkjet printer. Laser cutters come with
specific drivers that allow them to take what is on the computer, convert it into a format that
the laser cutter can read, and then allow the laser cutter to do its job. Many design software
packages support laser cutter drivers; it is pretty common among 2D design prorams, and
some 3D design software can also support laser cutter drivers when dealing with 2D drawings
or sketches. Here are a couple you may already be familiar with or may want to try out:

2D Design:

CorelDRAW: graphic design software with an extensive number of tools and

applications

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 Adobe Illustrator: Powerful graphic design software used to create high quality
designs
AutoCAD (free for students): Great drawing software, primarily used by
engineers and architects to create detailed drawings and product representations
Inkscape (free):Free, open source graphic design software

3D Design:

Solidworks:Engineering 3D design software with multiple packages for aiding in

design for specific applications
Autodesk Inventor (free for students): Professional mechanical design software
used to create and optimize designed systems
Autodesk Fusion (free for students): Cloud-based CAD platform used to help
designers through the entire designing, engineering and manufacturing processes.

6.4 Vector Cutting :

During a cutting operation, the cutting head fires a continuous laser at the material to
slice through it. In order to know where to cut, the laser cutter driver reads all of the
vector paths in the designed piece.
Once you send your file to a laser cutter, only lines that register as only hairline or
vector graphics with the smallest possible line thickness will be cut by the laser.
All other graphics, like any images or thicker lines, will be rastered, which I'll explain
in a bit. The laser, when supplied with the right settings, will cut all the way through
your material, so vector cutting is normally used for cutting out the outline of the part
as well as any features or holes that you want to cut out of the material.

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6.5 Laser Rastering :

Rastering is a lot different than vector cutting; instead of cutting all the way through
the work piece, the laser will burn off the top layer of the material you are cutting to
create two colour (and sometimes grayscale) images using the raster effect.
In order to raster materials, the laser will usually be set to a lower power than it would
when vector cutting material, and instead of shooting down a pulsing beam, it creates
fine dots at a selected DPI (dots per inch) so that the laser doesn't really cut all the
way through.
The DPI directly correlates to the image resolution and affects how fine an image
appears, exactly like image resolution on a computer.
By adjusting the DPI you can control the laser's effect on the material.
Rastering on some materials comes out really clearly, while you may not get exactly
what you expected on other materials.

Chapter 7 : Conclusion
During the period of 10 days of my internship at METALTEC PRODUCTS PVT. LTD.,I
learned about various types of Plasma Cutting Processes and Laser Cutting Processes and
Machines. I also got to know how to operate CNC Plasma and Laser Cutters.

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