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Cutting Equipment | Plasma | Cutting applications | Hole cutting

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Proud award winners: Kjellberg Development Manager Volker Krink, Managing Director Sales Thomas Kagemann and Managing Director of the Kjellberg holding company Dr. Michael Schnick (f.l.t.r.)
Kjellberg Finsterwalde Wins Innovation Award
Successful show participation with plasma cutting system „Q“ designed for Industry 4.0

The production of the new generation of plasma cutting systems is in full swing
Sales start of Q 3000 – Industry 4.0-capable Kjellberg
New plasma cutting system successful in industrial testing

Precise Holes – no Trick but Know-How

It is generally known that plasma can be used not only for cutting long-run contours but also for cutting holes into all electrically conductive materials. But how good is the quality of such cuts? The engineers of Kjellberg Finsterwalde's development department are constantly concerned with this topic which is again and again raised by customers and guests. Often, they are positively surprised by the high quality that can be achieved. Often, customers bring along their own drawings of parts to be cut which are then cut directly on-site in perfect quality. It is no trick to cut holes of very good quality but know-how which we teach our customers directly in training sessions.


Due to the physical build-up of the plasma arc, there is a lower limit, the minimum diameter. A rule of thumb says that the smallest possible hole has a diameter which is approximately one and a half times the plate thickness, for example with a 10 mm plate thickness the holes can be as small as 15 mm in diameter. However, the high-precisions plasma cutting systems of the HiFocus series allow cutting holes which are significantly smaller. With a 10 mm mild steel plate holes of 8 mm in diameter of very good quality are possible. Angular deviations are very low; the extraction caused by the move-in and move-out is barely visible. The cutting edges on the upper and lower sides of the material remain sharp-edged. This means that the heat-affected zone is very small and the surface of the material is not melted or rounded.


Of course, such cutting results do not only depend on the plasma cutting machine as the tool and the material to be cut but also on the optimum interaction between the guiding system and the height control unit. Guiding systems may react differently. The way a 2D guiding system copes with this task may differ from a robot, for example. Guiding system manufacturers, too, have different approaches and potentials how to solve this task. However, if the user knows about these interrelations the way is free for cutting precise and small inner contours.

 

Below you can see some examples which show holes of different sizes cut into a work-piece with a thickness of  10 mm. The smallest hole diameter amounts to 8 mm. The tolerance between upper and lower side amounts to less than 0.2 mm.

Cut contour with lead-in paths - hole cuttingHoles and contour cut upper sideHoles and contour cut - lower sideHoles - upper side
Minimum hole diameter 8 mmHole diameter 10 mmHole diameter 12 mmHole diameter 14 mm
Hole diameter 16 mmHoles and contour cut - side viewCutting a corner with a radius of 10 mmCutting a corner with a radius of 0.2 mm
Cutting a corner with a loopCutting a corner - cutting start
 
 
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