CNC Plasma Reference Guide Winter Quarter 2017
General Guidelines Shade 5 eye protection must be worn while the torch is in operation. Drill or punch holes within parts rather than using the plasma cutter. Dross the build up of material at the exit of the cut can be easily removed with a cold chisel. If at any time you have a question or are unsure of how to proceed, please do not hesitate to ask a CAED shop tech or staff member. Material Guidelines Your material must be clean and free of dirt and paint, materials that can be plasma cut include: Mild Steel Galvanized Steel Stainless Steel Aluminum Max sheet dimensions are 48 x 48 x ¾ DXF Guidelines Before exporting your linework as a DXF for use in the Torchmate CAD/CAM software please take note of the following guidelines. 1. Your linework needs to be made of closed curves. 2. Keep layouts simple, cut duplicate parts with single part profile. 3. Do not group your linework. 4. Do not turn your linework into blocks. 5. Any number of applications will export as a DXF, however you need to find the appropriate export options which will allow your linework to remain closed curves. 2
Exporting from Rhino 1. File > Export Selected Save as a DXF file and match your export options to the screenshot below. 3
Torchmate CAD/CAM Torchmate CAD/CAM is the application we will use to create the needed toolpaths for our part files. 1. File > Import... locate and open your DXF file, make sure options match screenshot below. 2. First make sure you set your fill color to black. Select all then click on the black swatch at the bottom of the screen, your part fill color should now be black. 3. Now make sure your parts are filled correctly, the filled area should match your desired end result. Toolpaths are offset away from the filled area to account for plasma kerf. If your parts are incorrectly filled you may need to use the break path and make path commands explained in the following steps or you may need to go back to Rhino and rejoin your linework and make sure they are closed curves. If your parts are correctly filled skip to step six. 4
4. Arrange > Break Path (ctrl+j) If the paths that make up your parts are incorrectly grouped you may need to first break the paths into their individual parts. 5. Arrange > Make Path (ctrl+h) Select all the paths associated with one part at a time, this command regroups the linework so that the software understands which direction to offset the tool paths and how to order the cutting. For example Interior holes are cut before exterior profiles. a. Part before it has been correctly arranged. b. Part after it has been correctly arranged. 5
6. Machine > Create Toolpath > Male Now that your parts are correctly arranged select all of your parts and use this command to generate your tool paths. 6
a. Template tab: Disregard this tab. b. Basic Cut tab: Refer to cut chart (located on the last page of this guide) for correct feed rate based on your material and material thickness, leave all others options at the settings pictured below. 7
c. Lead In/Out tab: In most cases these default settings will be adequate. 8
7. View > Show Tool Paths (Alt+J) Use this command to toggle off your toolpaths so that you can select and delete your original part linework. Use the same command to turn your toolpaths back on, your tool paths are all that should remain. 9
8. Select your toolpaths and move them to the bottom lefthand corner of your workspace so that the corner is highlighted pink (shown in screenshot). 10
9. Machine > Output (Alt+p) Use this command to begin the toolpath output process. 11
10. Do not change any of the settings found here. click the cut now button to generate your.gm file. 11. Once you have created your.gm file you can exit out of the Torchmate CAD/CAM application. 12
Torchmate Machine Setup Once you have generated your.gm file you are ready to set up the Torchmate gantry and plasma cutter. Follow these procedures carefully. 1. Place your sheet stock squarely on the water table. 2. Attach the ground clamp directly to your material. 3. Turn on the Accumove2 control box. 4. Turn on the Powermax65 Plasma Cutter. 5. Make sure compressed air line is attached to plasma cutter. 6. Make sure water level is just below top edge of metal slats. (ask for assistance if water level needs to be adjusted) 7. The torch is equipped with 45amp consumables. If you are cutting material thicker than ¼ then you will need to have a tech install 65amp consumables. Please reinstall the 45amp consumables at the end of your job. 8. Now you are ready to launch the Torchmate control software. 13
Torchmate VMD 1. Click hide on dialog box Please switch drives to on. 2. Click the Datum button to activate the gantry. 3. Click Select job to open your.gm part file. 4. In the Select Job dialog window click browse to locate your.gm part file. 14
5. Your imported part file should look something like this, red lines = cut, dashed lines = jog. 6. Find your materials correct AVHC data on the cut charts based on material and material thickness, you should only have to change Pierce Delay and Set Voltage. 15
7. The physical torch should be located at the lower lefthand corner of the water table, if it is not please ask a tech or shop staff for assistance. 8. Your desired program zero is the lower lefthand corner of your physical sheet stock. In some cases this will be same as your datum point, when it is not you must set it manually. 9. right click within the workspace at a point where you think your desired program zero point is and click move to here. Once the physical torch has moved and is close to your desired program zero you can use the yellow X and Y buttons to fine tune your exact position. 16
10. click Set Program Zero, this will move your toolpaths to the desired x,y, location. 11. You can toggle between Active Run and Dry Run, in dry run the physical torch will move through the entire job without striking an arc. This is important in determining if your material is located in the correct position and whether there are any unforeseen errors in your setup. With Dry Run active click Run Job. 17
12. If your Dry Run was successful set to Active Run and click Run Job, make sure you are wearing your shade 5 eye protection. 13. When finished cutting your job it is important to return the physical torch back to the datum point. To do this click on the Point tab, click Datum mode, then click Go. 14. Turn everything off. Clean everything up. 18