Technologies for processing metal structures and parts are widely used mechanical methods. Such operations are carried out by industrial machines, hand-held power tools, etc. More modern areas of processing solid materials are associated with thermal effects. And the cutting torch is the most accessible tool that implements this method.
Equipment Arrangement
Two-pipe or injector models of cutters are more often used, in which the supply of technical oxygen (working mixture) is divided into two streams. The top channel delivers gas to the handpiece head at high speed. Next, the mixture passes through the main nozzle of the mouthpiece. This part of the tool is responsible for the direct cutting of the workpiece. To control the process and heating characteristics, a control valve with a valve is provided. Usually this equipment is carried out on the upper part.corps. The lower tube, in turn, directs the gas into a special chamber for mixing with combustible gas. As a result, a balance of temperatures and speeds is ensured. In some areas, it turns out to be more profitable to have a three-pipe gas cutter device, in which mixing of two oxygen and one combustible streams inside the head is realized. The advantage of such models is to get rid of a special mixing chamber, the presence of which in itself was a danger of "backlash". In such situations, the mixture moves in the opposite direction.
How the cutter works
Unlike a mechanical tool, gas equipment does not directly contact the target area, but in the main part of the work it only mixes oxygen with combustible gas. As a result, the process of formation and direction of the preheating flame to the target workpiece is accompanied by the formation of an oxygen cutting jet. There are different variations of cutters that differ in the type of gas used, but fundamentally their functional purpose does not change. Unless the cutting technique may differ - for example, in terms of structure, cutting can be spear, surface or separation. And even this classification is irrelevant, since the universal gas cutter for metal allows the use of several modes with the possibility of cutting with a thickness of 3 to 300 mm. In this case, the stability of the equipment and the direction of the jet does not matter. The main thing is physical ergonomics when handling. The compact device can receive a variety of configurationscutting with proper skills.
Tool Varieties
When it comes to complex critical operations, the capabilities of a universal cutter may not be enough. Such models have a well-defined design and operational flexibility, but it is not suitable for many specialized tasks. For example, for remote jobs that require high productivity, it is recommended to use a propane torch that connects directly to the tank. Models of this type perform well on construction sites, carrying out complex and deep cutting in large metal structures. In contrast, there is a narrow line of small-format travel cutters that also connect to propane tanks, but operate at low power. In industrial workshops, kerosene cutters are more often used. This type of gas apparatus is capable of high performance, but only when connected to a central fuel supply. In this case, high safety requirements are imposed, so the burners are equipped with a wide range of protective systems.
Features of portable models
From a design point of view, this is the optimal solution for domestic use. The compact device is a nozzle for supplying a combustible jet to a metal surface. As in the case of propane models, it is connected to a gas collet cylinder, which acts as a source of the working mixture. It should also be noted that this is not a full-fledged cutter, but ratherburner. Therefore, during processing, controlled parameters of the intensity of thermal exposure will be important. In particular, a portable torch for domestic use maintains a torch temperature up to 1300 °C. Professional models of this class provide thermal effects up to 2800 ° C. As for the target materials, they include low-melting metals and alloys like aluminum, copper, tin, etc. But, again, by default, this tool melts the structure rather than cuts it. For efficient and accurate cutting without excessive deformation of the workpiece, use intensive thermal jet modes.
Cutter setup instructions
Before work, the tool is checked for technical and structural integrity. The quality of mating elements, functional parts and consumables should be assessed. Particular attention is paid to fittings - in particular, the tightness of the hose that will supply gas. Then a connection to the gas supply is made. This operation is performed using a threaded fitting. Depending on the hose model, either a right or left threaded connection device should be used. For example, if you plan to work with oxygen, you will use a right-hand thread. To eliminate the risk of breakdown and subsequent leakage, the gas cutter is seated on the can using a special mount with a lock. Even with accidental physical pressure on the fixation zone, this mechanism will not allow the hose to move away from the cylinder.
Workingprocess
The cutting process should be started only in the special equipment of the welder. As a minimum, the operator must wear goggles, gloves, and flame retardant clothing. The flame is directed towards the connected hose, and the latter, in turn, is positioned so that there is no interference with the physical manipulation of the cutter. The cylinder is placed away from the immediate workplace. According to the rules, a distance of 5 m must be maintained. Moreover, the process itself can be organized either outdoors or indoors, but with effective ventilation. When everything is ready for work, the heating mixture valve opens on the gas cutter. From this point on, the torch will begin to produce an active jet for cutting. Direct the device to the workpiece should be smooth, without jerks and vibrations. The thicker the structure, the longer the hold times should be.
Tool maintenance
After the working steps, it is necessary to revise the design of the tool again, checking the condition of individual parts. Store the torch only in a clean, low humidity environment without the risk of dust, dirt, or small objects entering the nozzle. If during operation a vacuum of the tool was detected, then the following actions should be performed depending on the type of construction:
- Disconnect the tip from the handle and clean the injector mechanism.
- Remove the screw and also clean the injector.
When cutting torches are used regularly,metal, intensive wear of individual elements is observed. You need to be prepared for this by stocking the appropriate spare parts. For example, copper mixing chambers, brass valve spindles (about 500 operating cycles), mouthpieces and handles are among the most worn out.
Safety requirements for metal cutting
It has already been said that the basis for successful work is equipment. But you should also consider some security rules that apply to an already started process. So, when the spindle rotates, all nuts and screws must have a strong clamp that prevents accidental loosening. The channels themselves can be opened for no more than 6 seconds. Further, through the open fitting, the instrument must suck in air at a pressure that should be 1.5 higher than the same level for each mouthpiece. All elements of the gas cutter connection are pre-cleaned and degreased. The tool should be stopped in stages, starting with a decrease in pressure in the nozzle until the gas supply is completely cut off.
Popular cutter models
As an inexpensive budget solution, we can recommend a simple but reliable KOVEA device. This is a universal cutting torch Torch KT-2008, which, in particular, is successfully used in factories, in auto repair shops and service stations. The flame power is 3.5 kW, but this is enough to process standard metal blanks and structures. As an alternative solution, we can offer the REDIUS R3P-01M and KRASS modelsR3P-02M. These are representatives of the middle segment, working with low-carbon steels. The advantages of these modifications include the setting of the power of the torch and resistance to kickback.
The "Svarog R3P-32-R" model also shows a high degree of reliability. This tool allows you to cut both sheet and section steel, including low-carbon steel. An analogue of R3P-32-R is another KOVEA cutting torch - performed by Torch TKT-9607. This model combines such advantages as functionality, performance and the option of piezo ignition.
How to choose the best option?
When buying, the materials used to make the tool, the diameter of the valve handle, supported cutting modes, etc. are taken into account. It is desirable to stick out brass from materials and refuse aluminum. In any case, fittings, fittings and fittings made of brass demonstrate high strength and durability. Plastic, for all its practicality and lightness, is undesirable due to rapid wear. With regard to the diameter of the valve handle, for typical operations requiring high performance, a standard size of 40 mm is recommended. At the same time, point one-time tasks will be more efficiently performed by a gas cutter with a smaller valve thickness. In choosing the type of tool and the principle of operation, much depends on the nature of the planned work. If the choice fell in favor of the injection model, then it is better to give preference to the version in which the mixing chamber is made of copper or its alloys.
Conclusion
Gas equipment in various fields combines very attractive performance and at the same time, working with it is accompanied by high risks in terms of safety. Nevertheless, a high-quality machine for processing metal blanks can be effective both in professional industries and in everyday life. For example, a gas cutter with a piezo ignition is quite suitable for garage work or the design of finishing frames for a house. Simple refinement of the metal profile during repair activities will be greatly facilitated if approached with a properly configured cutter. In addition, this tool practically does not surpass similar tools for cutting solid materials in terms of price. Average prices vary from 1.5 to 2 thousand rubles, and budget options are available for 600-700 rubles.
