What is Thermal Cutting?
Thermal cutting is one of the important production processes in the metal production and metalworking sectors, spanning domains such as structural engineering, machine fabrication, energy equipment manufacturing, shipbuilding, and plant manufacturing.

Essentially, thermal cutting harnesses energy in diverse forms to sculpt a wide array of shapes from both ferrous and non-ferrous materials, be it sheets or hefty slabs. These materials, commonly termed as “Flats” in the metal processing realm, encompass various grades. Conversely, there exist other metal types like angles, channels, beams, and pipes, and rods, collectively referred to as “Longs.” This series of articles will primarily delve into the cutting processes of Flats, with Longs to follow in subsequent discussions.

Thermal cutting can be classified based on the following criteria:
Material Type and Thickness:
The choice of thermal cutting process hinges primarily on the material type-ferrous or nonferrous-and its thickness.

Precision:
Each thermal cutting process maintains specific tolerances concerning basic process fundamentals, expressions, quality, and dimensional precision. Quality attributes, such as perpendi-cularity, angularity tolerances, and permissible roughness depth, are defined for distinct cutting methods.

Physics of the Cutting Process and Material Effects:
Cutting processes can be categorized by their underlying physics, including burning via oxidation, melting, and vaporization (sublimation). Process selection influences material type, tolerances, and chemical and physical reactions post-cutting.

Type of Production:
Production types range from manual tools to fully automated systems across various industries. Production volume and location-whether on-site, in enclosed areas, or typical factory settings-affect process selection.

Desired Post-Cutting Operations:
Thermally cut parts undergo various post-cut operations, including fitting, welding, grinding, bending, or heat treatment. The chosen process is influen-ced by the desired post-cut operation.

Energy Carrier:
Energy carriers, such as hot gases, electric gas discharge, or light beams, are utilized for metal removal. These carriers-gas, plasma, and laser-directly impact the physical and mechanical properties of the cut parts.

Application of Cut Part:
Consideration of mechanical stress, chemical reactions, fatigue, etc., determines the appropriate thermal cutting process based on the intended application of the cut parts.

Plates can undergo cutting through three primary processes: oxyfuel, plasma, and laser. In all three technologies, plates can be cut either straight or with bevel.

Why is bevel cutting necessary in fabrication units?
In any application, proper edge preparation for welding is crucial for achieving high-quality results, maintai-ning productivity, and minimizing costs associated with rework and downtime.
Preparing metal for welding typically involves cutting and beveling the base material. The level of care and preparation invested in the initial cut can significantly reduce the need for extensive post-processing later on.
Various tools can be employed for edge preparation, including torches, plasma cutters, shears, as well as manual tools like cutting wheels and mechanical bevel cutters. However, each method of edge preparation comes with its own set of advantages and disadvantages.

Ensuring proper preparation of metal for welding is essential for consistently producing high-quality results, maintai-ning productivity, and minimizing costs.
For instance, cutting with a right-angle grinder is cost-effective, portable, and requires minimal setup and maintenance compared to other options. However, achieving clean, straight cuts with this method demands a significant amount of practice and skill. Therefore, making the initial cut as clean, straight, and consistent as possible facilitates the production of quality results.
A clean and consistent gap between the two pieces to be welded results in a stronger and more consistent weld, requiring less filler metal. This not only reduces costs but also saves time in the welding process.

Where bevel cutting require?
Industrial bevel cutting is required in various sectors and applications where precise and angled cuts are necessary for welding or joining metal components. Some common industries and applica-tions where industrial bevel cutting is essential include:
Structural Steel Fabrication: Bevel cutting is crucial for preparing structural steel components such as beams, columns, and plates for welding in construction projects.
Shipbuilding: Shipbuilding requires precise bevel cutting of metal plates and sections to ensure proper fit-up and welding of hulls, decks, and other structural components.
Automotive Manufacturing: Bevel cutting is used in the fabrication of automotive frames, chassis, and body panels, ensuring accurate assembly and welding of vehicle structures.
Aerospace Industry: Aerospace applications require bevel cutting for the fabrication of aircraft components such as fuselages, wings, and engine parts to meet strict performance and safety standards.
Oil and Gas Sector: Bevel cutting is essential for preparing pipes, valves, and other components used in oil and gas pipelines, refineries, and processing plants.
Heavy Equipment Manufacturing: Industrial machinery and equipment manufacturers use bevel cutting for fabricating components such as frames, booms, and brackets, ensuring precise assembly and structural integrity.
Power Generation: Bevel cutting is employed in the fabrication of components for power plants, including turbine blades, boiler parts, and heat exchangers, to ensure efficient operation and reliability.
Metalworking and Fabrication Shops: Bevel cutting is commonly used in metalworking and fabrication shops for various applications, including custom fabrication projects, repair work, and prototype development.
Overall, industrial bevel cutting is essential wherever precise and angled cuts are required to facilitate welding, assembly, and fabrication processes in diverse industries and applications.
Messer Role in Plate Cutting:
Messer offers comprehensive plate cutting solutions tailored to meet the diverse needs of industries ranging from automotive and aerospace to construc-tion and energy. Their cutting-edge technologies and equipment ensure precision, efficiency, and cost-effectiveness in plate cutting processes. Here’s an overview of Messer’s plate cutting solutions:

Oxyfuel Cutting: Messer’s oxyfuel cutting systems provide robust and reliable cutting solutions for thick carbon steel plates. Utilizing a combination of oxygen and a fuel gas, such as acetylene or propane, oxyfuel cutting achieves high-quality cuts with minimal dross and excellent edge squareness.

Plasma Cutting: Messer’s plasma cutting systems utilize advanced plasma tech-nology to cut a wide range of materials, including carbon steel, stainless steel, aluminum, and non-ferrous metals. With high cutting speeds, precision, and versatility, Messer’s plasma cutting solutions are ideal for various applications, from thin gauge to thick plate cutting.

Fiber Laser Cutting: Messer’s fiber laser cutting systems deliver exceptional speed, accuracy, and flexibility for cutting a variety of materials with unmatched precision. With fiber laser technology, Messer’s cutting solutions offer superior edge quality, minimal heat-affected zones, and reduced operating costs compared to traditional cutting methods.

Combination Cutting: Messer offers hybrid cutting solutions that combine oxyfuel, plasma, and fiber laser technolo-gies to maximize cutting efficiency and versatility. These integrated systems allow users to optimize cutting processes for different material types, thicknesses, and applications, achieving optimal results with minimal setup time and material waste.

Automation and Integration: Messer’s plate cutting solutions are designed for seamless integration into automated production environments, enabling increased productivity, reduced labor costs, and improved workflow efficiency. From robotic cutting systems to advanced software solutions, Messer offers a range of automation options to streamline plate cutting operations and maximize throughput.

Bevel solutions: Messer has a range of bevel tools from manually positioned tools for simple beveling to automated bevel tools in oxyfuel, plasma & Laser processes for complicated contour beveling and to produce all preparatory work in next to no time.

Overall, Messer’s plate cutting solutions provide industry-leading performance, reliability, and versatility, empowering manufacturers to achieve superior cutting results while optimizing their production processes.

Messer Cutting Systems India Pvt. Ltd.
Web : in.messer-cutting.com