The technology for processing metal structures and parts in widespread use are mechanical methods. Similar operations are carried out by production machines, hand-held power tools, etc. More modern areas of processing solid-state materials are associated with thermal exposure. And a gas cutter is the most affordable tool that implements this method.
Equipment device
More often, two-pipe or injection models of torches are used, in which the supply of technical oxygen (working mixture) is divided into two streams. The upper channel delivers gas to the tip 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 of the body. The lower tube, in turn, directs the gas into a special chamber for mixing with combustible gas. The result is a balance of temperatures and speeds. In some areas, it turns out to be more profitable to use a three-pipe device for a gas torch, in which the mixing of two oxygen and one combustible stream 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 represented the danger of a “back strike”. In such situations, the mixture moves in the opposite direction.
Torch principle
Unlike a mechanical tool, gas equipment does not directly contact the target area, and in the main part of the work it only mixes oxygen with combustible gas. As a result, the process of forming and directing the heating flame to the target workpiece is accompanied by the formation of an oxygen cutting jet. There are different variations of the torches, which differ in the type of gas used, but in principle their functional purpose does not change. Unless the cutting technique may differ - for example, the structure of the cutting can be lance, surface or dividing. And even this classification is irrelevant, since the universal gas cutting torch 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 flow of the jet does not matter. The main thing is physical ergonomics when handling. With a compact device you can get a variety of cutting configurations with the proper skills.
Tool varieties
If it comes to complex critical operations, then the capabilities of a universal cutter may not be enough. Such models have a pronounced structural and operational flexibility, but it is not suitable for many specialized tasks. For example, for remote work requiring high productivity, it is recommended to use a propane gas cutter that connects directly to the cylinder. Models of this type perform well on construction sites, carrying out complex and deep cuts in large metal structures. Conversely, there is a narrow line of small-format tourist cutters, which also connect to propane cylinders, but operate at low power. In industrial plants, kerosene carvers are more often used. This type of gas equipment is capable of providing 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 portable models
From the point of view of design, this is the best solution for working in a domestic environment. The compact device is a nozzle for supplying a combustible jet to a metal surface. As in the case with propane models, it is connected to a gas collet cylinder, which acts as a source of the working mixture. It should also be borne in mind that this is not a complete cutter, but rather a burner. Therefore, during processing, the controlled parameters of the intensity of the heat exposure will be important. In particular, the portable gas torch for domestic use maintains the torch temperature up to 1300 ° C. Professional models of this class provide thermal effects up to 2800 ° C. As for the target materials, these include fusible metals and alloys like aluminum, copper, tin, etc. But, again, by default, this tool rather melts the structure, rather than cuts it. For efficient and accurate cutting without excessive deformation of the workpiece, you should use intensive modes of supply of a thermal stream.
Torch Setup Instructions
Before work, the tool is checked for technical and structural integrity. You should evaluate the quality of the mating elements, functional parts and consumables. Particular attention is paid to fittings - in particular, the tightness of the hose that will supply gas. Then, a connection is made to the gas supply source. This operation is performed using a threaded fitting. Depending on the model of the hose, a right- or left-threaded device for connection should be used. For example, if you plan to work with oxygen, then the right-hand thread will be used. To eliminate the risk of breakdown and subsequent leakage, the gas cutter is seated on a spray can with the help of 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.
The working process
The cutting process should be started only in the special equipment of the welder. At a minimum, the operator should have glasses, gloves and clothing with refractory properties. The flame is directed towards the failed hose, and the latter, in turn, is positioned so as not to interfere with physical manipulations with the cutter. The cylinder is located 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 valve of the heating mixture opens on the gas cutter. From this moment, the burner will begin to produce an active jet for cutting. The machine should be guided to the workpiece smoothly, without jerking or hesitation. The thicker the structure, the longer should be the intervals with exposure to the melt.
Tool maintenance
After working steps, it is necessary to revise the design of the tool again, checking the condition of the individual parts. The torch can only be stored in a clean place with a low humidity coefficient without the risk of dust, dirt or small objects entering the nozzle. If during the operation a vacuum of the tool was detected, then the following steps should be performed depending on the type of construction:
- Detach the tip from the handle and clean the injection mechanism.
- Remove screw and also clean injector.
With the regular use of gas torches for metal, intense wear of individual elements is observed. You need to be prepared for this by stocking up appropriate spare parts. For example, the most worn out include copper mixing chambers, brass valve spindles (about 500 operating cycles), mouthpieces and handles.
Safety requirements for metal cutting
It has already been said that the basis for the successful conduct of work is equipment. But you should also consider some safety rules that apply to the process that has already begun. So, when rotating the spindle, all nuts and screws must have a strong clamp, preventing accidental unscrewing. The channels themselves can be opened for no more than 6 seconds. Further, through an open nozzle, the tool should suck in air at a pressure that should be 1.5 higher than the same level for each mouthpiece. All elements of the gas torch connection are pre-cleaned and degreased. The tool should be stopped in stages, starting from lowering the pressure in the nozzle until the gas supply is completely stopped.
Popular torch models
As an inexpensive budget solution, you can recommend a simple, but reliable KOVEA device. This is a universal torch torch KT-2008, which, in particular, has been successfully used in factories, car repair shops and service stations. The flame power is 3.5 kW, but this is enough to process standard metal workpieces and structures. As an alternative solution, the REDIUS R3P-01M and KRASS R3P-02M models can be proposed. These are representatives of the middle segment, working with low carbon steels. The advantages of these modifications include setting the power of the torch and resistance to reverse shock.
A high degree of reliability is also shown by the Svarog R3P-32-R model. This tool allows cutting of both sheet and steel, including low-carbon steel. An analog of R3P-32-P is another KOVEA gas 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?
Upon purchase, the materials used to make the tool, the diameter of the valve handle, the supported cutting modes, etc. are taken into account. It is desirable to bulge out the materials from the materials and refuse aluminum. In any case, the fittings, connecting parts and brass covers show high strength and durability. Plastic, with all its practicality and lightness, is undesirable due to rapid wear. As for the diameter of the valve handle, for typical operations requiring high performance, a size of 40 mm is recommended. In this case, single point tasks are more efficiently performed by a gas cutter with a smaller valve thickness. In choosing the type of tool and the principle of action, 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 operational characteristics and, at the same time, working with it is associated with high risks in terms of safety. Nevertheless, a high-quality apparatus for processing metal billets can be effective both in professional industries and in everyday life. For example, a gas cutter with piezo ignition is quite suitable for garage work or designing finishing frames for the home. A simple refinement of the metal profile during repair activities will be greatly facilitated if you approach it with a properly configured cutter. In addition, and at a price this tool practically does not surpass similar means for cutting solid-state materials. Average prices range from 1.5 to 2 thousand rubles, and budget options are completely available for 600-700 rubles.