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Round tube CNC Plasma Cutting Machine

Differences: ,Waterjet Cutting, Laser Cutting, Plasma Cutting And Wire Cutting

Waterjet Cutting

Water cutting, also known as water jet, is a high-pressure jet-cutting technology, which is a device that uses high-pressure water cutting. Under the control of the computer, the product workpiece can be engraved at will, and it is less affected by the material quality.  Water cutting is divided into two methods: no sand cutting and sand cutting.

3D AC 5 axis cutting head

Laser Cutting

Laser cutting is to use the focused high-power laser to directly irradiate the product workpiece, so that the irradiated raw materials are quickly melted, vaporized, burned or reached the point of ignition, and at the same time rely on the high-speed cyclone output coaxially with the light to blow off the molten material, And then finish cutting the product workpiece. Nowadays, CO2 single-pulse laser generators are generally used, and laser cutting is one of the thermal cutting methods.

laser cutting machine for sheet metal​

Plasma Cutting

Low-temperature plasma arc cutting is a process that uses the heat generated by high-temperature and low-temperature plasma arcs to partially melt (and volatilize) the metal material at the workpiece wound and removes the molten metal material by the angular momentum of high-speed low-temperature plasma to form a wound way.

plasma cutting machine

Wire Cutting

Spark discharge wire cutting machine (Wirecut Electrical Discharge Machining, commonly known as WEDM), which belongs to the scope of metal processing, spark discharge wire cutting production and processing (Wirecut Electrical Discharge Machining, commonly known as WEDM), is sometimes called wire cutting. Wire cutting can be divided into fast wire cutting, medium wire cutting and slow wire cutting. The wire speed of fast-moving wire spark discharge wire cutting is 6-12m/s, and the wire electrode moves back and forth at high speed, and the cutting accuracy is weak. The medium-feeding wire-spark wire cutting is based on the fast wire-cutting to realize the DC frequency conversion multiple cutting function, and it is a new technology developed in recent years. The wire speed of slow wire spark discharge wire cutting is 0.1m/s, and the wire electrode performs unilateral movement at low speed, and the cutting accuracy is very high.

Differences among laser cutting, waterjet cutting, plasma cutting, and wire cutting

The laser cutting machine has a wide range of applications. It can cut metal materials and non-metal materials. CO2 laser cutting machines can be used to cut non-metal materials, such as fabrics and leather products. Fiber laser cutting machines can be used to cut metal materials. The deformation of the plate is small.

Round tube CNC Plasma Cutting Machine

Waterjet cutting belongs to thermal cutting, jet deformation, high cutting surface, no need for secondary processing, and it is easy to carry out secondary processing if necessary. Waterjet cutting can open holes and cut all materials, with faster cutting speed and flexible processing specifications.

Plasma cutting machine can be used to cut various metal composite materials such as stainless steel, aluminum, copper, pig iron, carbon steel, etc. Plasma cutting has obvious thermoelectric effect, low precision, and the cutting surface is not easy to carry out secondary processing.

plasma cutter for cnc table

Wire cutting can only cut conductive substances, and coolant is required during the cutting process, so it cannot cut paper, leather and other materials that are non-conductive, waterproof, and afraid of coolant pollution.

cnc water jet cutting machine

The laser cutting machine has a wide range of applications. It can cut metal materials and non-metal materials. CO2 laser cutting machines can be used to cut non-metal materials, such as fabrics and leather products. Fiber laser cutting machines can be used to cut metal materials. The deformation of the plate is small.

Laser Cutting Machine Manufacturers

Waterjet cutting belongs to thermal cutting, jet deformation, high cutting surface, no need for secondary processing, and it is easy to carry out secondary processing if necessary. Waterjet cutting can open holes and cut all materials, with faster cutting speed and flexible processing specifications.

Plasma cutting machine can be used to cut various metal composite materials such as stainless steel, aluminum, copper, pig iron, carbon steel, etc. Plasma cutting has obvious thermoelectric effect, low precision, and the cutting surface is not easy to carry out secondary processing.

Wire cutting can only cut conductive substances, and coolant is required during the cutting process, so it cannot cut paper, leather and other materials that are non-conductive, waterproof, and afraid of coolant pollution.

Cutting thickness comparison:

The application of laser-cut carbon steel in industrial production is generally below 20MM. The cutting capacity is generally below 40MM. The industrial production and application of stainless steel plates are generally below 16MM, and the cutting capacity is generally below 25MM. And with the increase in the thickness of the product workpiece, the cutting rate is significantly reduced.

The thickness of water cutting can be thick, 0.8-100MM, or even thicker materials.

The plasma cutting thickness is 0-120mm, and the best cutting quality range is about 20mm. The low-temperature plasma system is the most cost-effective.

The thickness of wire cutting is generally 40-60mm, and the thickness can reach 600mm.

Cutting thickness comparison:

The application of laser-cut carbon steel in industrial production is generally below 20MM. The cutting capacity is generally below 40MM. The industrial production and application of stainless steel plates are generally below 16MM, and the cutting capacity is generally below 25MM. And with the increase in the thickness of the product workpiece, the cutting rate is significantly reduced.

The thickness of water cutting can be thick, 0.8-100MM, or even thicker materials.

The plasma cutting thickness is 0-120mm, and the best cutting quality range is about 20mm. The low-temperature plasma system is the most cost-effective.

The thickness of wire cutting is generally 40-60mm, and the thickness can reach 600mm.

Cutting speed comparison:

Use a laser with an output power of 1200W to cut a 3mm thick high-carbon steel plate at a cutting speed of 600cm/min; cut a 5mm thick polypropylene resin plate at a cutting speed of 1200cm/min. The cutting efficiency that spark discharge wire cutting can achieve is generally 20 to 60 cubic millimeters per minute, and the Z maximum reaches 300 cubic millimeters per minute; obviously, the laser cutting speed is faster and can be used for mass production.

The speed of water cutting is very slow, and it is not suitable for large-scale mass production.

The cutting speed of plasma cutting is relatively slow, and the relative accuracy is low. It is more suitable for cutting thick steel plates, but the inner hole has a slope.

For the processing of metal materials, wire cutting has higher precision, but the speed is relatively slow. Sometimes it needs to use other methods to cut holes and wires to cut, and the cutting size is very limited.

Cutting accuracy comparison:

The laser cutting wound is thin and narrow, the two sides of the slit are parallel to the surface and vertical to the surface, and the specification accuracy of the cut parts reaches ±0.3mm.

Low-temperature plasma can achieve within a millimeter;

Water cutting will not cause thermal deformation, and the accuracy is ±0.mm. If a dynamic water cutting machine is used, the cutting accuracy can be improved, and the cutting accuracy can reach ±0.02mm, eliminating the cutting inclination.

The processing accuracy of wire cutting is generally ±0.01~±0.02mm, and the Z maximum reaches ±0.004mm.

Comparison of the overall width of the slot:

Laser cutting is more precise than plasma cutting, and the kerf is small, about 0.5mm.

The kerf of plasma cutting is larger than that of laser cutting, about 1-3mm;

The slit of water cutting is about 10% larger than the diameter of the knife tube, generally 0.8mm-1.3mm. As the diameter of the sand knife tube expands, the wound becomes larger.

The kerf width of wire cutting is the smallest, generally around 0.1-0.3mm.

Cutting process performance comparison:

The surface roughness of laser cutting is not as good as that of water cutting, and the thicker the material, the more obvious it is.

Water cutting always does not change the material of the raw material near the cutting seam (the laser belongs to thermal cutting, which will change the material near the cutting area.

Materials Suitable For

  • Waterjet Cutting
    • It is a versatile cutting method that can handle a wide range of materials, including metals (such as stainless steel, aluminum, and titanium), non – metals (like stone, glass, ceramics, composites, and rubber), and even some food products. It is especially useful for cutting materials that are difficult to cut with other methods due to their hardness, brittleness, or heat – sensitivity.
  • Laser Cutting
    • Commonly used for cutting metals (such as mild steel, stainless steel, and aluminum), non – metals (including plastics, wood, and fabrics), and some composites. However, the effectiveness of laser cutting depends on the material’s ability to absorb the laser wavelength. For example, CO₂ lasers are better for non – metals, while fiber lasers are more suitable for metals.
  • Plasma Cutting
    • Primarily used for cutting electrically conductive materials, mainly metals such as carbon steel, stainless steel, and aluminum. It is less effective for non – conductive materials as it requires an electrical circuit to form the plasma. The thickness of the material that can be cut is relatively large, making it a popular choice for heavy – duty metal cutting applications.
  • Wire Cutting
    • Wire cutting is mainly used for cutting hard and electrically conductive materials such as tool steels, carbide, and hardened alloys. It is particularly well – suited for cutting complex shapes in these materials, such as the production of precision molds and dies.

Cutting Speed

  • Waterjet Cutting
    • The cutting speed of waterjet cutting is relatively slow compared to plasma and laser cutting, especially when cutting thick materials. The speed depends on factors such as the material’s hardness, the thickness of the material, and the water pressure. For example, cutting a 1 – inch – thick stainless – steel plate with waterjet cutting might take several minutes, while a thinner material like 0.25 – inch – thick aluminum could be cut more quickly.
  • Laser Cutting
    • Laser cutting can be quite fast, especially when cutting thin materials. The speed is affected by the laser power, the material’s thickness and type, and the complexity of the cutting pattern. For instance, a fiber laser can quickly cut through a 0.1 – inch – thick mild – steel sheet at a high speed, but the speed may decrease as the material thickness increases.
  • Plasma Cutting
    • Plasma cutting is known for its relatively high cutting speed, especially for thick metal sheets. It can cut through thick materials more quickly than waterjet cutting. However, the speed may vary depending on the plasma cutting system’s power and the material’s characteristics. For example, a high – power plasma cutter can rapidly cut through a 2 – inch – thick carbon – steel plate.
  • Wire Cutting
    • Wire cutting is a slow process compared to the other three methods. The speed is limited by the electrical discharge rate and the wire feed rate. It is used for precision cutting where speed is often sacrificed for accuracy and quality, such as in the production of intricate parts for the aerospace or electronics industries.

Cost and Equipment Complexity

  • Waterjet Cutting
    • The equipment for waterjet cutting is relatively complex and expensive. It requires a high – pressure pump, an abrasive delivery system, and a precision – engineered cutting head. The cost of consumables (especially the abrasive) can also add up. However, the maintenance costs are moderate. The initial investment is high, but it can be a cost – effective solution for cutting a wide variety of materials, especially in cases where heat – induced damage needs to be avoided.
  • Laser Cutting
    • Laser – cutting equipment can be expensive, especially high – power lasers and precision motion – control systems. The cost also depends on the type of laser (CO₂ or fiber). The operating cost includes the energy consumption of the laser and the cost of replacement parts such as lenses and laser tubes. Maintenance requires trained technicians due to the complexity of the equipment. However, for high – volume production of precision – cut parts, the cost per cut can be relatively low.
  • Plasma Cutting
    • Plasma – cutting equipment is generally less expensive than laser – cutting equipment. The initial investment is lower, and the operating cost mainly depends on the cost of gases and the power consumption. The equipment is relatively simple to operate and maintain, but the cut quality may not be as high as laser – cutting, which might lead to additional post – processing costs in some applications.
  • Wire Cutting
    • Wire – cutting equipment is also complex and expensive. It requires a precision – controlled wire – feed mechanism, a high – voltage power supply, and a dielectric fluid – handling system. The cost of the wire electrode and the dielectric fluid can be significant. The equipment is used for high – precision applications where the cost per part may be justified by the quality and complexity of the cuts.

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