FLAME CUTTING

BY
B.LAKSHMAN
2017109025
 INTRODUCTION
• Flame cutting is oxygen cutting
process in which the appropriate
part of the material to be cut is
raised to ignition temperature by
an oxy-fuel gas flame.

• It is also called as OXY-FUEL

GAS CUTTING.

• The process is now about 111-

112 years old as it was patented
in 1901 by THOMAS
FLECHER to crack safe.
Fundamentals Of Flame
Cutting
Advantages:-
• A relatively smooth cut is
produced.
• Very thick steel can be cut.
• The equipment is portable.
• Underwater cutting is possible with
some adaptations.
• The equipment lends itself to
automatic processes in
manufacturing
 How is flame cutting
performance increased?
• The choice of fuel type and nozzle
selection make the flame cutting
process faster, which, in turn,
reduces labor costs.
• The choice of gas used in the process
depends on whether the operation is
manual or mechanized and on the
material type. For instance, acetylene
has a flame temperature of 3160
degrees Celsius, making it ideal for
thin sheet and bevel cutting.It is not
suitable for the cutting of larger
metal plates as it is expensive.
Three types of OXY-ACETYLENE
FLAME produced
A)neutral flame
• The neutral flame is the flame in which
the amount of oxygen is precisely enough
for burning, and neither oxidation nor
reduction occurs
B)CARBURISING(REDUCING) FLAME
• When more acetylene present than
oxygen in the flame then it is said to
be carburizing flame or reducing
flame.
• The carburizing or reducing flame is
mostly used because of its need for
oxygen will reduce oxides, such as
iron-oxide or copper-oxide.
• Non-ferrous alloy and carbon steels
requires a carburizing flame
Carburising flame
 C)Oxidizing flame
• If there is an excess amount of
oxygen, the flame is said to be
oxidizing flame.
• The flame is slightly hotter than the
neutral flame.
• zinc compound materials may need
oxidizing flame.
Three types of oxyacetylene flame
 ACETYLENE - HISTORY
• The name for acetylene was suggested
in 1860 by Berthelot who was first to
study the properties of this gas which
had been discovered in 1836.
• Acetylene was first used around 1892
for lighting (especially for car headlight)
• It was the invention by Charles Picard in
1901 of the oxy-acetylene blowpipe
which led to the rapid development of
the acetylene industry as a result of the
many uses of the oxyacetylene flame in
steel welding, scarfing, hard facing,
surface cementation, and oxygen
cutting lamps.
OXWELD acetylene company ads in 1912
ACETYLENE-GENERATION
Generation of Acetylene
• Acetylene is generated by the
reaction of calcium carbide with
water.

• The calcium carbide used to generate

acetylene is manufactured by the
reduction of high quality lime by the
carbon of selected cokes in the high
temperature of an electric furnace.
 Properties of Common
Fuel Gases
Methylacetylene-
Propane propadiene (MPS)
Acetylene Propylene Natural
Gas
Chemical formula C2H2 C8H8 C3H6 C3H4 CH4
Neutral flame Fº 5,6000 4,580 5,200 5,200 4,600

Primary flame
heat emission Btu/ft 507 255 433 517 11

Secondary flame
Btu/ft3 963 2,243 1,938 1,889 989
Look for the rest in Table 6.1 from text
FLAME CUTTING
 Figure 14: Flame-cutting torch with one oxygen needle valve (left)
and one acetylene needle valve (right)

Figure 15 : Machine cutting torch. Figure 16 : Shape cutting machine.

 Equipment

1. Gas cutting torch.

2. Pressure regulators.
3. Gas cylinders.
4. Goggles
5. Gloves and apron.
6. Spark lighter
7. Chipping hammer and wire brush
8. Hoses and valves
 EQUIPMENT

Gas cutting torch Gas cylinder

 CONTD…..

Gloves and apron CHIPPING HAMMER

 CONTD……
Spark lighter Pressure regulators

*The maximum safe working pressure for acetylene is 15 PSI !

 CONTD…

HOSES AND VALVES GOGGLES

step 1:
Getting Started- Inspect the
Equipment
1. Inspect the cone end, coupling nut, and
torch head for dirt, dust, oil, grease, or
damaged parts. Dirt and dust can be
removed with a clean cloth.
• CAUTION: If oil, grease or damaged parts
are detected, DO NOT USE! Report it to
the instructor immediately!
step 2:
Inspect the “O”Rings
2. Inspect the cutting attachment cone
end for missing or damaged “O”
rings. Damaged or missing “O”
rings can allow gases to mix and will
cause backfires or backflash.
step 3:
Inspect the Cutting Tips
3. Inspect the torch head. The tapered
seating surfaces must be in good
condition.
• If dents, burns or burned seats are
present, the seat must be resurfaced.
• If the torch is used with a bad seat,
backfire or backflash may occur.
 step 4:
Setting up the Cutting Head
4. Connect the cutting attachment to
the welding torch handle and
tighten the coupling nut, using
hand pressure only.
• Wrench tightening may damage “O”
rings and create a faulty seal.
HAND TIGHT ONLY
step 5:
Tip Selection
5. Select the required size and type of
cutting tip.
step 6:
Attaching the Cutting Tip
6. Insert the tip in the cutting
attachment head and tighten
securely with an open-end wrench.

Wrench Tight Connecting Nut

Process of flame cutting
STEP 1: PREHEATING
• The process consists of preheating the
metal to be cut to its ignition (oxidation)
temperature, i.e., above 870°C in case of
steel.

• The preheating is done by oxy-acetylene

gas flame, which is supplied from
surrounding openings of the cutting
torch
Step 2:oxidation
When this temperature is attained, a
jet of high pressure oxygen from a
central opening of the cutting torch
is directed on the red hot metal.
• The metal is rapidly oxidized, and
slag is formed. This slag is washed
out by the jet of oxygen.
• The processes of cutting steel
consist of the following reaction:
• 3Fe + 2O2 → Fe3 O4 + heat (27,000
cal.)
The successfulness of gas cutting process
depends upon two factors:
• (i) It employed only when the ignition
(oxidation) temperature of the metal
being cut is lower than its melting point.
• (ii) The process involves ensuring that
the melting points of the formed oxides
are lower than that of the base metal
itself.
• Although acetylene is commonly used
as a fuel in this process, other gases can
also be used including butane, methane,
propane, natural gas. Hydrogen is
sometimes used as a fuel gas, especially
under water to provide a powerful pre-
heating flame.
 FLAME CUTTING

• Diagnosis: Perfect Cut

• Diagnosis: Dirty Tip

• Diagnosis: too fast

• Diagnosis: Too Slow

 SAFETY!
1. Never use oil or other petroleum based products on
oxyacetylene fitting or connections.
2. Never have the working pressure of acetylene
above 15 psi. Acetylene is very unstable above 15
psi and high explosive.
 SAFETY!
3. Never Stand in front of or behind a regulator
when opening the cylinder valve. Always stand
so that the cylinder is between you and the
regulator.
4. DO NOT open acetylene cylinder valves more
than 1 ½ turns, preferably ¾ turn.
5. Point Flame away from people, equipment, and
any flammable materials.
6. If you detect a leak on any part of the
oxyacetylene equipment, turn off all valves and
tell the instructor.
Comparison of kerf
Kerf is defined as the width of
material that is removed by
a cutting process.
CUTTING CIRCLES - FLAME
CUTTING

….
 Case study

ATM HEISTS
ATM HEISTS
INDUSTRIAL APPLICATION
CNC FLAME CUTTING
 Quiz time

1)Mixing _______ and water will produce acetylene

gas.
A: calcium carbide
B: potassium carbonate
C: carbon dioxide
D: acetylene carbide
 Quiz time

2)To prevent the occurrence of flashbacks, a ________

should be installed between either the torch and hoses
or regulators and hoses.
A: a two way check valve.
B: flame screen.
C: flashback arrestor.
D: three way check valve.
 Quiz time

• What is the maximum safe working gauge pressure

for acetylene gas?
A: 8 psig (55 kPa)
B: 15 psig (103 kPa)
C: 22 psig (152 kPa)
D: 30 psig (207 kPa)