1. Plasma Oxy Fuel Band Saw Sawz-All Portable Disk (Angle) Grinder
Metal Cutting
Plasma
Oxy Fuel
Band Saw
Sawz-All
Portable Disk (Angle) Grinder

2. Plasma Arc Cutting (PAC)
Cutting process that uses an arc and a high-velocity, ionized gas coming through a small nozzle to cut ALL metals
Link:

3. CNC PAC
CNC

4. PAC Plasma is a super heated gas that is ionized.
Ionized- Electrons in the gas have broken away form their atoms and will conduct electricity.

5. PAC
How it cuts
The plasma gas (compressed air) is forced through a constricting nozzle and heated by the arc which reaches 18,000 to 25,000°F
Most plasma cutters require at least 70 PSI

6. Advantages of PAC Can cut ANY metal Super fast setup & cutting speeds
Torch can’t cut aluminum or stainless, PAC slices right through it.
Super fast setup & cutting speeds
Little distortion (warping) from heat
No hazardous gasses (O2 or Acetylene)

7. Disadvantages Plasma Torch is expensive
Portability (needs electricity & compressed air)
70PSI is need to run most PAC machines
Metal fumes created can be a health hazard

8. Safety/ Maintenance A minimum of a #4-5 filter shield should be used
Need proper ventilation to remove harmful fumes
Do not allow Pilot Arc to continue for long periods of time

9. Setting the PAC Torch Thickness Current Travel Speed 1/16” 35 amps
175 in/min
1/8”
40 amps
90 in/min
1/4”
40 in/min
80 amps
100 in/min
3/8”
18 in/min
55 in/min
1/2”
20 in/min
35 in/min

10. PAC Setup & Procedure Clean metal Hook up ground cable
Draw cutting pattern or template on metal
Place electrode as close to base metal as possible without touching.
1/16-1/8” from metal
Position torch at a 70 to 90° angle
Pull the trigger & pull torch across metal

11. Cutting Jigs
* Clamp angle iron in place for straight cuts!

12. Cutting Speed Too Slow- Molten metal (dross) will collect on bottom
Too Fast- Metal will not be cut all the way through
Sparks may fly upwards

13. Dross
Most will chip away
Increases with slow travel speeds

14. Consumables Electrode Nozzle Swirling Ring (orange)
Causes plasma to swirl
While these parts are all referred to as consumables, it is the electrode and nozzle that wear and require periodic replacement.

15. Oxy-Fuel Cutting
LINK

16. Oxy Torpedo

17. Oxy-Fuel Cutting
A torch is used to heat metal to its kindling temperature.
A stream of oxygen is then forced into the metal, burning it into a metal oxide that blows out of the kerf as slag.

18. Does Metal Burn?
Virtually all materials will burn if they are first heated to their ignition temperature.
Steel ignition temp is when it is cherry red, ° F
Oxygen burns preheated metal and blows it away from the work piece.

19. Oxy-Acetylene Torch Setup

20. Oxy-Fuel Cutting Process
Oxygen (green) 20-23lbs | Acetylene (Red) 5-7lbs
Open cutting valve to set oxygen
Clean metal
Draw line or make jig if straight cut is needed
Hold tip ~ 1/8” above metal
Preheat metal to cherry red color
Open oxygen valve and push
Angle tip slightly toward direction of cut

21. - Can’t convert for welding or brazing -
OFC Equipment
Combination Cutting Torch
Straight Cutting Torch
- Can’t convert for welding or brazing -

22. Torch Tip Standard flame exits through outer ring.
Oxygen blasts through center orifice

23. Flame Types
Carburizing Flame – to much acetylene, black smoke, too much carbon
Neutral Flame – MINT!
Oxidizing Flame - Too much oxygen, hear rushing air, very blue flame

24. Neutral Flame
Look for a defined blue cone

25. OFC Cutting Tip Information

26. Cutting Quality – Grain Pattern
Quality Cut
Extremely Fast
Irregular Pressure
Extremely Slow

27. Bending Metal Metal ductility increases with heat.
Easier to bend and form.

28. You need to do your homework first!
Hardening Metal
Different steels have different methods
Heat steel to ignition temp. ( *F)
Test with magnet (loses magnetic properties)
Quench in oil (peanut, mineral, motor) for “X” amount of time
Immediately place in an oven to temper.
Steel becomes very hard but becomes brittle
You need to do your homework first!

29. Temperature Indicating (Heat) Sticks
Identifies the temperature of metal
Different sticks melt at different temperatures.
Preheating metal before welding

30. Safety Proper PPE Keep tanks upright & chained!
4-5 Face Shield, pants, gloves, jacket
Keep tanks upright & chained!
Let tanks settle for at least 15 minutes after changeover.
Stand to the side of regulators
Always cap unused tanks
Acetylene tanks ¼ turn max

31. Horizontal Band Saw (Metal)

32. Horizontal Band Saw

33. Types of Blades

34. Band Saw Blades Teeth Per Inch (TPI) Blade Speed / RPM
More teeth/inch= hard metals
Less teeth/inch= soft metals
Blade Speed / RPM
Soft materials: increase RPM
Hard Materials: decrease RPM

35. Blade Tension Blade will seize in work piece if too lose.
Blade may snap if too tight.
Tool of choice for long cuts

36. Guide Adjustment Tool of choice for long cuts
Adjust guides to ensure a straight cut.
Blade will wonder on long cuts.

37. Band Saw safety Rules Burrs on cut pieces are sharp.
Use special care when handling pieces with burrs
Check for proper tension on the blade
Secure piece in vice
Check & adjust guards
Use a brush to clean chips
Keep your hands away from moving parts
Stop machine before making adjustments

38. Band Saw Operation Mark metal where cut is to be made
Mount solidly in the vice
Support tail with jack stand
Check tension and condition of blade
Set guide as close as possible
Turn on saw
Slowly open gravity feed (use proper force)
Lubricate with cutting oil
Clean saw when finished

39. Vertical Band Saw Safety Rules

40. Safety Rule #1
Keep all guards in place.

41. Safety Rule #2
Adjust the blade guards to within 1/8” to ¼” of the stock.

42. Safety Rule #2 - Continued
Blade guards that are over ¼ inch above the work will lead to accidents and reduces the accuracy of your cut.

43. Safety Rule #3
Maintain the stock flat on the table.

44. Safety Rule #3 - Continued
Never hold the stock ‘above’ the table, the material must remain flat on the table surface at all times.

45. Safety Rule #4 Don’t cut round stock on the band saw.
The round stock may roll into the blade causing an accident.
Only the instructor should perform this task while using a miter gauge.

46. Safety Rule #5
Concentrate your attention on the job at hand.

47. Safety Rule #5 - Continued
Do not interrupt others while using power equipment.
Stay focused until the blade has stopped moving.

48. Safety Rule #6
Never leave the machine operating while unattended.

49. Safety Rule #7
Keep the work area clean.

50. Safety Rule #7 - Continued
Scrap wood or tools on the floor or the bandsaw table will lead to accidents and injuries.

51. Safety Rule #8
If the blade comes out of the guides or breaks, stop the machine immediately by turning off the power.
Do not open the access door to the machine until the wheels have come to a complete stop.
Have the instructor reposition or install a new blade.

52. Safety Rule #9
Do not reach across the saw line.

53. Safety Rule #10
Never back material out of a cut until power has been turned off and the motion of the blade has stopped.

54. Safety Rule #11
Always use a push stick when sawing small stock.

55. Safety Rule #12
Do not hold the stock in line with the saw blade.

56. Safety Rule #12 - Continued
Hold the stock to the sides of the cutting line.

57. Safety Rule #13
Keep your hands and fingers several inches from the side of the blade.

58. Safety Rule #13 - Continued
Remember to keep your hands clear of the table insert.

59. Safety Rule #14
Use ‘relief cuts’ on tight curves to avoid breaking the blade.

60. Chop Saw Manually cuts metal with a fiber composite saw blade.
Cut angles
Link:

61. Safety Rules Always wear safety glasses Inspect wheel before each use
Clamp all metal before cutting, adjust if necessary
Support tail of stock with blocks

62. Safety Rules Watch where sparks are aimed
Let cutting wheel do the work
Do not cut pieces less than 6 inches.

63. Blades Inspect blade before each use.
Chips, cracks, etc.
Remove blade when it reaches ½ of its original diameter.
Do not over tighten blade

64. Cutting Angle Iron
Make sure the peak is facing UP

65. Cutting Flat Bar Stock
Width of bar should be vertical.

66. Cutting Channel Iron
Base of material should point up

67. Reciprocating Saw (Sawz-All)

68. Blades Always use the right blade for the job.
Unplug the tool before making adjustments.
Don’t carry the saw by the cord.
The blades get HOT!

69. Safety Always rest the heel on the work piece.
Prevents binding & kickback

70. Blades
Applications are identified by labels on the packaging and blade.
Most Common:
Wood
Metal
Multi-purpose

71. More Blades

72. Hand Tools Tin Snips Aviation Snips Scribers Steel Blue Soap Stone
Paint Markers

73. Tin Snips

74. Aviation Snips Left, Straight, Right
Red should cut Right, but it doesn’t.

75. Layout Tools
Scribe
Scratch-Awls

76. Layout Fluid Fast drying ink Scribing or punching Magnifies marks
Remove with steel wool or alcohol

77. Identification Tools
Soap Stone
Paint Marker

78. Stamping Stamp your initials on projects or pieces
ONE blunt hit with a hammer
Solid surface

79. Summary Follow the safety rules.
Use the laboratory tools only for their intended purpose.
Follow the directions and safety guidelines as listed by the machine’s manufacturer.
ASK QUESTIONS!!!!