You Big Dummy!!!!

[Runs With Scissors]

So there I am, in the shop playing with my new CNC Plasma cutter.

Until now, I have had very good luck with it. Most of my problems are "CAD" related. I am currently using Fusion 360 and it has been kicking my a$$ for about 6 month's, but I am getting "better".

So I decide to make a sign for the annual "take the girls ice fishing" trip this year.

I have only made a few parts and one sign so far, but I have never had any problems.....yet.

I decide to use 16 gauge mild steel, just because I have used it in the past with good success and so far it has "resisted" warping pretty well.

So I toss a chunk of it onto the machine and do a "dry run" to get it lined up.....so far so good.....


Then I hit "run" and it starts off fine.

Well about 10 seconds into the cut I notice something is off......

The cuts are not going "through the material", they are just going about 1/2 way through.




The cuts look like total crap, so I abort the mission and start troubleshooting.

To me it appears as if there is not enough "current" to make a proper cut, or possibly the machine is going too fast?

So I "up" the current setting on the machine and hit "go" again....

Not wanting to waste material and since I have already screwed up this section, I decide to "cut over" the already screwed up section to "test it out".



Nope.....still jacked up.

WTF??????

So then I start changing cut speeds and messing with the plasma machine......This all takes about an hour.

Still sh!t!!!!!!!!!!

So I decide/conclude that the the drawing is "too detailed" for my machine and I decide that I need to "redo" the design to something simpler....

I also need a "Tool Rack" for my Lathe, so I go upstairs and embarrassingly enough, about 1.5 hours later, I have a simple "tool holder" designed.

So its off to the Langmuir to cut it out.

Nope!!!!! Same jacked up cuts........Now I am pissed, and begin my usual "cussing temper tantrum"........I dont even have the witts to take a picture of it I am so damn mad....

Then I look over, and it hits me like a sack of hammers........







The ground clamp was off..........

I felt both 'relieved" and "stupid" simultaneously..

After grounding it properly, I get this...





Now it's time to see if my "original sign design will work.....






Yep......all good now.

Amazing how a proper grounding clamp can change things....hahahah

Just one small "snafu' is that piece in the center must have been a little too "tight" for my machine.




So a few minutes on the "TIG" machine and a little "body work" it should paint up nice.

 

[DustyRusty]

When all else fails, check the grounds, it doesn't matter whether it's a car, tractor, plasma cutter, etc. Check the grounding!

 

[WI_Hedgehog]

Also keep track of the number of pierces on the tip consumable, too many and it can arc and blow up the whole head. There's an arc starter material in the middle that gets consumed (like a florescent light). One indicator of a worn consumable is the draft angle increases.

 

[Yooper]

BTDT. I forgot the ground on my welding bench many years ago and I noticed smoke coming from my fluorescent light that was part of the bench. Current found its way home through the ground wire. Looks like it found a partial path on your table but I wonder where?

 

[je1279]

Finished products look good though. I'm pretty sure we've all had a moment or two like this during our lives.

 

[GreensvilleJay]

at least you didn't fry the alternator !
curious, does the display NOT show actual 'cutting current' or similar data?

 

[woodman55]

Just another one of those "educational moments" a guy never forgets.

 

[Runs With Scissors]

at least you didn't fry the alternator !
curious, does the display NOT show actual 'cutting current' or similar data?

Thats a good question.

I'm still pretty new to this "CNC" thing.

If it does, then it must be on the "computer" somewhere, but I don't know where its at.

The plasma cutter has an "old school" knob that you set, but I should look around and see if there is some sort of "actual current value" displayed somewhere while it is cutting.

 

[Runs With Scissors]

Current found its way home through the ground wire. Looks like it found a partial path on your table but I wonder where?

I am thinking through the feet somewhere.

 

[Runs With Scissors]

If I have one complaint about this machine, it would be that the small'ish holes tend to not come out well.



so I have to usually "chase them" with a drill bit.





But the bigger holes come out very well.

Man this sure beats the hell out of actual "drilling" old school style.




Now to bend her up on the homemade brake......





But wait!!!!!!

If I only had a "air over" press brake.......Oh wait...... I do!!!!!!

So a few minutes at the brake and whaaalaa.

I "over bent" it a little, but a little work, and I get it "good nuff"



A few minutes with the TIG machine.




Now its ready for "paint"

 

[hagrid]

Kerf seems wide for 16ga. Mebbe try turning down the power on the torch.

I'm assuming your schnozzle isn't blasted to hell and back after that extended starting circuit display.

 

[Runs With Scissors]

Kerf seems wide for 16ga. Mebbe try turning down the power on the torch.

I'm assuming your schnozzle isn't blasted to hell and back after that extended starting circuit display.

I will try turning it down next time.

I might need to make some test passes and post the results on my "white board" for future use.

Schnozzle should be good still.

It does not have many cuts on it, but your right, that it is something I should check now and again.

 

[North Idaho Wolfman]

First picture I said, NO GROUND.
Why?
Because I've BTDT, almost caused a plasma cutter to grow wings and fly.

Are you drying your air?
You can get starting blowouts, shluf, and splatter from wet air.

 

[Sidekick]

I drilled a hole through my concrete floor and drove a ground rod 7 feet into the ground. Grounded my plasma table slats to that with a #2 wire. Also us the plasma machine clamp on the metal. Eliminates ground loops from the plasma cut to the table that can mess with my torch height controller. Hypertherm has fine cut Consumables for excellent results in thinner metal. That rough spot looks like your torch break away may have some play or acceleration is set high for radiuses.
I bought a set of cobalt drills for opening up small holes because those cuts are hard.

 

[jaxs]

Finished products look good though. I'm pretty sure we've all had a moment or two like this during our lives.

A moment or two in a lifetime is one thing but not to call any names certain individuals can't get momentum before moments have them derailed.

 

[Runs With Scissors]

First picture I said, NO GROUND.
Why?
Because I've BTDT, almost caused a plasma cutter to grow wings and fly.

Are you drying your air?
You can get starting blowouts, shluf, and splatter from wet air.

Yea, besides draining the tank on a frequent basis, I also plumbed about 50 feet of 1" black pipe to "possibly" help slow and cool the air before it enters a dessicant style filter. From there it goes into a Moto-Guard "toilet paper" filter, then to the machine.

Eventually I am thinking of a series of copper pipes to help cool the air, but I haven't gotten that far yet.

 

[Runs With Scissors]

I drilled a hole through my concrete floor and drove a ground rod 7 feet into the ground. Grounded my plasma table slats to that with a #2 wire. Also us the plasma machine clamp on the metal. Eliminates ground loops from the plasma cut to the table that can mess with my torch height controller. Hypertherm has fine cut Consumables for excellent results in thinner metal. That rough spot looks like your torch break away may have some play or acceleration is set high for radiuses.
I bought a set of cobalt drills for opening up small holes because those cuts are hard.

Thats a fantastic idea regarding the ground.

There is some sort of grounding strap for the house, only 2 or 3 feet from the machine, so I am going to use it.

 

[GreensvilleJay]

There's several 'inter-cooler' designs on the web, nice one uses Chevy A/C 'rad' between compressor head and tank. One of those 'winter projects' I should get to doing,seeing how I have the 'rad' sitting here collecting dust...The 'trick' is to get get as much water out ASAP and cool down the air BEFORE using descicant(sp) prills.

 

[Runs With Scissors]

There's several 'inter-cooler' designs on the web, nice one uses Chevy A/C 'rad' between compressor head and tank. One of those 'winter projects' I should get to doing,seeing how I have the 'rad' sitting here collecting dust...The 'trick' is to get get as much water out ASAP and cool down the air BEFORE using descicant(sp) prills.

Yes, there seems to be quite a "debate" on this.

I think the argument is "before or after" the head.

Sort of reminds me of the "Oil/filter wars" that rages on...and on...and on........

I'm not sure which team I "identify with" yet......

 

[Smokeydog]

You will be happy to know that “senior moments” only increase with age. Constantly amused by the challenges my mind and body now effect and direct my work. If most inventions happen by accidents, I’m close to figuring out fusion in a bottle any day now.

Envious of your CNC capabilities.