Cutting pipes with plasma pipe cutters using special centralizers is common today almost everywhere. A modern range of pipe cutting machines covers all the technologies that are necessary for high-quality pipe material.

Pipe cutting machines can be mobile, robotic, and also include any post-processing steps.

From the point of view of quality results, the main difference between cutting pipes from classic pipe cutting machines based on autogen and similar technologies consists in an absolutely precise processing of the metal surface.

In terms of the functionality of the equipment, plasma cutting of pipes also has its differences, which consist in the possibility of carrying out auxiliary operations - surface preparation, seam peeling, chamfering and grooving. Another distinctive feature of plasma equipment for cutting steel pipes is the use of precise drives that allow it to move through the pipe.

Due to its wide capabilities, as well as its affordable cost, cutting pipes with plasma is one of the most popular technologies for precise cutting of pipes of a large range of diameters and practically any alloys.

We offer to see how the automatic plasma cutting line for CNC tubes works:

How is metal pipe cut by plasma?

Equipment for cutting a profile pipe can be worn on it anywhere, which certainly expands the possibilities of its use. The tool for cutting pipes is attached to the surface to be machined with special clamps.

For movement along the pipe, special rollers are provided in the construction of the equipment for cutting pipes, while pipe compression is provided with a metal centralizer tape. It is possible to move the device for cutting pipes with plasma either by means of a mechanical shift manually or by means of an actuator.

In addition to the translational movement along the pipe, the pipe cutter can also rotate: this movement is remotely controlled using a simple panel.

Did you know? The geography of using plasma pipe cutters for pipes is quite wide: the correct determination of the parameters of their work makes it possible to use this equipment not only in the European part of Russia, but also in the Far North and the Far East.

In practice, the technology of plasma tube cutting is successfully implemented in a variety of equipment. To confirm this fact in this article, we present several examples of plasma cutting from the manufacturer Eckert.

Example 1. Robot

This six-axis robot allows the torch to be moved a distance of up to 2 m, which makes it possible to cut pipes of large diameter or long length. Moreover, Eckert engineers managed to develop a sophisticated innovative system that allows you to perform even a complex shape on the surface of pipes, while chamfering it at the same time.

The combination of 3D metal pipe cutting devices, modern software and technological expertise has allowed the company to create a very flexible nesting system used to prepare complex pipe designs.

Example 2. Universal pipe cutting ESR

The ESR-300 systems are an inexpensive, unified solution for the heat treatment of pipes and profiles by cutting. As an additional option, the Eckert system can be used in conjunction with portal CNC systems. Unlike conventional plasma cutting machines, the ESR system allows figure cutting of pipes, which reduces investment costs and maintenance costs, as well as optimizes the use of production space.

Did you know? A special machine that allows you to rotate the pipe during the cutting process, as well as during the welding process, is called a “welding rotator”.

The movement of the calipers to hold the pipe in a horizontal position and the welding rotator in the universal pipe cutting system from Eckert is synchronized and controlled by the CNC. With the help of ESR-300 equipment, pipes with a diameter of 50-300 mm and thickness up to 10 mm can be processed. Other modifications of the system - ESR-600 and ESR-900 - are used for pipes with a diameter of 150-600 and 300- 900 mm, respectively.

Example 3. Installing plasma cutting of Koral pipes

This modern installation of plasma tube cutting is specifically designed for enterprises working in the manufacture of structures for construction and pipelines. The independent Eckert Koral system is designed for those cases when it is necessary to focus on extremely accurate pipe cutting. Depending on the modification, Koral can process pipes with a diameter of 50–300, 150–600 and 300–900 mm, respectively.

The main task with which the installation of Koral plasma cutting successfully copes is the manufacture of tubular elements involved in the creation of complex structures (for example, if it is necessary to connect several pipes into one unit). Thanks to the CNC, the Koral unit automatically rotates the pipe being machined and ensures accurate positioning of the torch at the plasma cutting point.

As an option, the installation can be supplemented with a 3D head, which allows making a cut of any complexity in one pass and performing chamfering. The 3D head smoothly changes the angle of inclination and automatically performs the torch turns during the cutting process.

In addition to Eckert products, popular equipment for plasma tube cutting are TubeTailor machines (a line specifically for SteelTailor pipes). You can see how this machine works in the following video:

Cutting metal products with the help of plasma technology has found its application among enterprises of various directions.

This method of cutting metals is based on the formation of plasma using an electric arc in a gaseous environment and is suitable for working with products up to 50 mm thick.

Thus, this metal handling technology is a great solution for .

Advantages and disadvantages of plasma sharp

First you need to understand what a plasma is. Plasma cutters mounted on installations for plasma cutting of pipes will cope with almost any source material. It can be either stainless steel or copper, aluminum or other non-ferrous metals.

The benefits of plasma cutting are also invaluable. These include the following advantages:

• Ability to work with various materials (stainless steel, zinc, copper, aluminum, black steel);
• High cutting speed with low and medium metal thickness;
• Lack of thermal deformation due to the slight heating of the workpiece;
• High level of security when working with equipment;
• Excellent cut quality as well as high surface finish;
• The possibility of cutting a complex geometric shape;
• The low cost of the procedure and quick payback.

However, not everything is as good as it seems. There are also negative aspects when carving metal products using a plasma cutter and equipment with it.

• When working with colored edges, it is possible to melt the edges;
• Calcining the edges (but not significant);
• When titanium is cut, an alpha layer is formed with a thickness of up to 15 mm.

Nevertheless, the plasma system is currently considered the most versatile, high-speed and high-quality way to cut metals and products from it.

Plasma Pipe Cutting Equipment

Today, the process of preparing pipes for further welding is impossible without the use of machine tools. Modern equipment is equipped with CNC (numerical software devices) and special software. All this allows you to quickly and easily, and most importantly accurately cut large diameter pipes along any trajectory, which in turn significantly increased the quality of connections, as well as the overall productivity of labor.

However, other types of equipment are increasingly being used for plasma cutting of large diameter pipes. These are pipe cutters that are equipped with centralizers. If we compare them with the classic equipment for cutting pipes, the advantages are obvious.

Virtually all plasma equipment specifically designed for cutting large diameter pipes has additional support functions, which include:

• Preliminary surface preparation;
• Seam cleaning;
• Chamfering;
• Splitting for welding.

In order to precisely move along the pipe surface, special drives are provided in the device of this equipment, which drive the rollers by means of which the equipment moves along the pipe.

Cutting large diameter pipes by hand is ineffective and sometimes impossible. Therefore, it is more convenient to use special methods for this treatment: mechanized or thermal.

Use of the grinder

The most affordable is cutting pipes using grinders. The method is applied not only in domestic but also in industrial conditions. All the necessary safety measures must be taken. Using an angle grinder, it is possible to cut pipes of large diameter, but this will significantly cut the cutting wheels.

Roller mechanism

If a roller device is used, several of them move along the surface, gradually thinning layer. The clamp is adjusted using screw mechanisms. Of course, this method can not be called fast. Therefore, if you need to process a large number of parts, the method does not fit

Gas cutting

Often in this case gas cutting is used. At the same time, fuel is added to the oxygen supply (for example, kerosene, propane, or acetylene). This causes melting, and the gas flow at this time blows the molten metal particles. The technology is characterized by high speed and, at the same time, low cost. Some equipment is equipped with several cutting heads, which allows to obtain highly accurate results.

Plasma cutting

Cutting pipes of large diameter can be carried out by thermal method. One of them is a plasma view. The metal is melted due to high temperature. Air which can be ionized from the discharge by electricity can also take part in the formation of plasma. It is used not only automated, but also manually. But, of course, to obtain a perfect result using an automatic installation.

Waterjet and laser cutting

In some cases, pipe cutting is performed using relatively new methods, which include:

• hydroabrasive processing;
• laser processing.

The first was used recently. It consists of using a stream consisting of water and abrasive materials supplied at high speed under a pressure of over 200 atmospheres. Formed ultra-small section easily affects not only metal, but also brick, concrete and other materials. The technology is very fast. In this case, it is not the pipe itself that is heated, but only the cut point.

Laser cutting of pipes is no less promising. The recent fantasy today has gained real shape and is already widely used for industrial purposes. Work in this way provides a highly accurate result. Moreover, it is characterized by the speed of work. After cutting, there is no need for a cutting place to undergo additional processing. They already look perfectly smooth and clean. Currently, the laser method is not so often used for these purposes, but its use is possible and is being implemented more and more often. Therefore, the high price today, maybe tomorrow will drop significantly.

Services Ltd. "Metal"

Our company offers cutting of large diameter pipes to order. We have been working with metal structures for a long time, and specialists deal with different processing. They know exactly when they need one way or another. The high level of qualification, as well as the most modern equipment used in the work, provides a 100% guarantee of a perfect result. Whatever the volume of the order, we will deal with it as soon as possible. The low price of services that are accepted in Moscow and the Moscow region, you will be pleasantly surprised.

In the process of using pipes in production or construction, there is often a need for their machining (including cutting), i.e. changing shape, size and configuration. Today's technology has allowed us to completely replace the manual cutting of pipes. It was replaced by high-tech methods, including:

• plasma cutting;
• laser cutting.

Such services are successfully provided by Verna-SK. We carry out these works as soon as possible at very reasonable prices.

Plasma and laser cutting - a new word in metal processing technology

These two methods are the most promising. Their main difference is accuracy and cost. Laser cutting is the perfect cut, high accuracy and speed with minimal material consumption. It is usually used when it is necessary to manufacture parts of complex shape that do not require further processing afterwards.

Plasma cutting is used to produce blanks, not parts. In this case, the cost of such processing is lower than when using a laser. In addition, the method of plasma cutting can be processed metal of greater thickness than with the use of a laser.

If it is necessary to cut a metal whose thickness does not exceed 20 mm, the laser cutting method will be more efficient. If the thickness of the metal exceeds the mark of 20 mm - plasma cutting is used. The use of plasma and laser cutting of metal and pipes has the following advantages:

• reduction of the final cost of the product, which is achieved due to the absence of the need to use additional tools for processing;

• reduction of time costs;
• full automation of the entire cycle;
• excellent quality and high precision pipe cutting.

For all questions regarding the order of cutting pipe services, please contact the Verna-SK managers by calling the number listed on the company's website.