Hypertherm HPR400XD - User Manual

Thick metal cutting techniques
For HPR400XD™ and HPR800XD plasma cutting systems
White paper
Introduction
Using plasma to successfully cut thick metal requires more
skill and technique than using plasma on thinner metal. The
thick metal cutting techniques described in this document
may be needed from the beginning of the cut with an edge
start all the way to finishing the cut with a completely
severed part.
Note: Unless otherwise specified, for the purposes of this document,
thick metal consists of stainless steel and aluminum from 5 inches to
6.25 inches (125 mm to 160 mm) thick. The techniques detailed in this
document were developed using 304L stainless steel. Materials used for the
development of this white paper were based on U.S. customary units
(inches). Metric conversions are provided for reference.
This document describes thick metal cutting techniques
developed for the HPR800XD that can help manage the
large plasma lag angles associated with thick metal cutting.
It also describes the timing and sequencing needed to be
successful in piercing up to 4 inches (100 mm) stainless
steel and 3 inches (75 mm) aluminum. This document is
broken into four sections:
• Thick metal cutting techniques overview on page 2 is an
overview of different lag angle management techniques for
thick metal cutting that covers a plasma cut from the
beginning to completion.
• Dogleg lead-out details for thick stainless steel on page 4
covers the details of a special lead-out technique (known as
the dogleg or acute angle lead-out) that can allow you to
completely sever a stainless steel part up to 6.25 inches
(160 mm) thick.
• Stationary piercing (up to 3-inch stainless steel and
aluminum) on page 8 describes the timing and sequence to
be followed to perform stationary piercing on 3 inch
(75 mm) stainless steel and aluminum.
• Moving pierce technique (up to 4-inch stainless steel) on
page 10 describes a moving pierce technique for thick
stainless steel that can be used with both the HPR800XD
and the HPR400XD. This technique, combined with
PowerPierce
®
technology, extends the pierce capacity for
the HPR800XD to 4 inches (100 mm) and for the
HPR400XD to 3inches (75mm).

Hypertherm HPR400XD Specifications

General

Brand	Hypertherm
Model	HPR400XD
Category	Cutter
Language	English

Summary

Thick Metal Cutting Techniques Overview

Edge Start and Initial Setup

Details on torch positioning, motion delay, and initial cut speed for thick metal cutting.

Cornering Methods for Thick Metal

Techniques for managing corners in thick metal cuts, including rounding, delay, and slow-down.

Completing Thick Metal Cuts

Methods for finishing thick metal cuts, including lead-out and dogleg techniques.

Dogleg Lead-Out for Thick Stainless Steel

Dogleg Lead-Out Method Explanation

Explains the dogleg lead-out technique for achieving complete severance of thick stainless steel.

Overshoot Calculation and Correction Factors

Details on calculating overshoot distance and the application of relevant correction factors.

Dogleg Geometry Limitations and Segments

Discusses geometric limitations and segment parameters critical for the dogleg method.

Dogleg Parameters and Geometry Illustration

Provides specific dogleg parameters and a geometric illustration for various thicknesses.

Stationary Piercing Techniques

Stationary Piercing Process Steps

Step-by-step guide for stationary piercing, covering height, timing, and motion controls.

Stationary Pierce Timing Diagram

Visual timing diagram illustrating the sequence of operations for stationary plasma piercing.

Moving Pierce Technique Overview

Moving Pierce Basics and Safety

Introduction to moving pierce, its benefits, equipment requirements, and safety precautions.

Moving Pierce Lifter Sequence

Detailed sequence of torch lifter movements during the moving pierce process.

Moving Pierce Implementation Details

Moving Pierce Table Motion Sequence

Sequence of table movements to establish evacuation channels during moving pierce.

Embedded Part Program Parameters for Moving Pierce

Specific program parameters for controlling the moving pierce sequence on EDGE Pro controllers.

Thick Stainless Steel Moving Pierce Parameters

Comprehensive tables of moving pierce parameters in English and metric units.

Sample Moving Pierce Program Code

Example EDGE Pro CNC code for performing a moving pierce on a 3-inch stainless steel plate.