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More 16 Gauge issues

Cut quality issues can be discussed here, most common issues have been discussed here and should help you.
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Andynorris
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More 16 Gauge issues

Post by Andynorris » Mon Apr 11, 2022 3:20 pm

I hope someone can help me out here. It’s the old topic of 16 gauge problems. I have read through all I can on here and tried all the different settings to no avail. Nothing I try or do seems to work. I’m using a Power Max 105 with a JD2 8 X 4 table. I’m hoping someone has the same set up and can help me. I’ve tried Fine Cut and 45 amp consumables. The cut quality is awful, and I’ve never managed to complete the piece I’m trying to cut. The piece is a 2’ diameter Tree of Life. I’ve seen more intricate pieces done and I have to say I wouldn’t expect to have this many issues with this set up. Can anyone help ?

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Re: More 16 Gauge issues

Post by harrymorley » Mon Apr 11, 2022 3:54 pm

I suspect its a speed , amperage issue. 16 ga should use a fast cut speed if using high amperage....put some scrap on the table and try cut speeds around 150 ipm or so with 40 amp or so amperage. I dont use a water table so I keep spraying surface with water from a hand held water sprayer to reduce buckling . Some experimenting with speed and amps will hopefully help . Nowadays , I use nothing less than 14 ga . It was easier to figure out. Also cold rolled steel cuts cleaner with less dross.

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Re: More 16 Gauge issues

Post by adbuch » Mon Apr 11, 2022 4:46 pm

Andynorris wrote:
Mon Apr 11, 2022 3:20 pm
I hope someone can help me out here. It’s the old topic of 16 gauge problems. I have read through all I can on here and tried all the different settings to no avail. Nothing I try or do seems to work. I’m using a Power Max 105 with a JD2 8 X 4 table. I’m hoping someone has the same set up and can help me. I’ve tried Fine Cut and 45 amp consumables. The cut quality is awful, and I’ve never managed to complete the piece I’m trying to cut. The piece is a 2’ diameter Tree of Life. I’ve seen more intricate pieces done and I have to say I wouldn’t expect to have this many issues with this set up. Can anyone help ?
What are your settings for cut height, piece height, cut speed, pierce delay time, current, and corner acceleration?
David

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Re: More 16 Gauge issues

Post by Andynorris » Mon Apr 11, 2022 5:28 pm

Harrymorley. I will be trying the 14 gauge, i've heard it's less trouble.
Adbuch. Cut heights i've tried from 0.06 to 0.08. Pierce height i tried 0.15. Pierce delay 0.04. Cut speed i reduced down to 170 ipm. Current i had down to 45 amps with the volts at 78. This was based on a post from whiskymike from a few years ago. As far as corner acceleration, i never altered this.
I forgot to mention that i have SheetCam. not sure whether that makes any difference or not. I see some people have built their own tools for thin gauge.
I figured i must be doing something wrong as the equipment is reputable. Also using a lot of consumables which leads me to believe somethings amiss.

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Re: More 16 Gauge issues

Post by adbuch » Mon Apr 11, 2022 5:30 pm

Hypertherm plasma cutter? Which model?
David

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Re: More 16 Gauge issues

Post by otisa2007 » Mon Apr 11, 2022 5:50 pm

My biggest problem with the 16ga is trying to run too fast the height control can't react quick enough i use a plasmacam with a powermax 45 and only run 120ips at45 amps this works for me as i cut a bunch of 16ga and with my setup have pretty well eliminated 90% of my problems i also set the height control a little higher than normal to account for the material bowing

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Re: More 16 Gauge issues

Post by Andynorris » Mon Apr 11, 2022 6:05 pm

adbuch wrote:
> Hypertherm plasma cutter? Which model?
> David

I'm running the Powermax 105

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Re: More 16 Gauge issues

Post by Andynorris » Mon Apr 11, 2022 8:34 pm

otisa2007 wrote:
> My biggest problem with the 16ga is trying to run too fast the height
> control can't react quick enough i use a plasmacam with a powermax 45 and
> only run 120ips at45 amps this works for me as i cut a bunch of 16ga and
> with my setup have pretty well eliminated 90% of my problems i also set the
> height control a little higher than normal to account for the material
> bowing

I'll try those settings. Thanks.

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Re: More 16 Gauge issues

Post by JeepGuy » Mon Apr 11, 2022 9:12 pm

pics of cut quality?

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Re: More 16 Gauge issues

Post by adbuch » Mon Apr 11, 2022 9:32 pm

otisa2007 wrote:
Mon Apr 11, 2022 5:50 pm
My biggest problem with the 16ga is trying to run too fast the height control can't react quick enough i use a plasmacam with a powermax 45 and only run 120ips at45 amps this works for me as i cut a bunch of 16ga and with my setup have pretty well eliminated 90% of my problems i also set the height control a little higher than normal to account for the material bowing
So you are using a 45 and not the 45xp. I use the FineCut consumables on anything 10 ga. and thinner, and cut at Hypertherm "book specs". The FineCuts are only available for machines using the Duramax torch. I am using either my 45xp or powermax 85 and both use the Duramax torch.
For your powermax 45, I would recommend that you try using the 30 A consumables and the settings shown below.

In addition, if you are using Design Edge with the advanced machine control upgrade, then adjust your corner acceleration down from the factory setting of 0.2G to something like 0.03 to 0.05G. This will allow you to run at the higher cut speeds while still maintaining your cut details.

I don't think you said exactly what you are cutting. For straight line cutting, it probably doesn't matter. But for things like artwork with finer details, then lower your corner acceleration. Ideally you would be using the FineCut consumables, but they are not available for the 45 unless you upgrade to the Duramax torch.

David
powermax 45 cut chart.jpg
machine control settings.jpg

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Re: More 16 Gauge issues

Post by Andynorris » Tue Apr 12, 2022 9:00 am

harrymorley wrote:
> I suspect its a speed , amperage issue. 16 ga should use a fast cut speed
> if using high amperage....put some scrap on the table and try cut speeds
> around 150 ipm or so with 40 amp or so amperage. I dont use a water table
> so I keep spraying surface with water from a hand held water sprayer to
> reduce buckling . Some experimenting with speed and amps will hopefully
> help . Nowadays , I use nothing less than 14 ga . It was easier to figure
> out. Also cold rolled steel cuts cleaner with less dross.

Do you use Fine Cut or 45 amp consumables ?

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Re: More 16 Gauge issues

Post by adbuch » Tue Apr 12, 2022 5:04 pm

By the way, I do a lot of cutting of 22 ga. cr steel and the cuts are all great. I am using FineCuts at book settings.
David

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Re: More 16 Gauge issues

Post by Andynorris » Wed Apr 13, 2022 1:27 pm

Just curious adbuch. What machine are you using and there any known issues with using a Powermax 105 on thin gauge. I have heard that they are very voltage sensitive in relation to the THC.

Thanks

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Re: More 16 Gauge issues

Post by adbuch » Wed Apr 13, 2022 4:15 pm

Andynorris wrote:
Wed Apr 13, 2022 1:27 pm
Just curious adbuch. What machine are you using and there any known issues with using a Powermax 105 on thin gauge. I have heard that they are very voltage sensitive in relation to the THC.

Thanks
I am using my Hypertherm Powermax 85 for cutting 22 ga. steel on my Plamacam DHC2 table. I use the same settings and consumables (FineCuts) that I would use with my 45xp.
David

PS. As I mentioned previously, try using the 30 amp consumables for your machine. You will most likely have better results for thin material.

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Re: More 16 Gauge issues

Post by otisa2007 » Wed Apr 13, 2022 5:09 pm

I am running the older powermax 45 which it will cut at the rated speed i keep it slowed down due to the height control I only have the basic plasmacam height control and most of my problems with 16 ga come from the tip dragging on the metal the biggest drawback to the slower cut speed is the dross and most of my 16ga cuts are artwork on straight line stuff like my ash pans for the fire pits i can run the faster speeds

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Re: More 16 Gauge issues

Post by adbuch » Wed Apr 13, 2022 5:11 pm

otisa2007 wrote:
Wed Apr 13, 2022 5:09 pm
I am running the older powermax 45 which it will cut at the rated speed i keep it slowed down due to the height control I only have the basic plasmacam height control and most of my problems with 16 ga come from the tip dragging on the metal the biggest drawback to the slower cut speed is the dross and most of my 16ga cuts are artwork on straight line stuff like my ash pans for the fire pits i can run the faster speeds
Is your tip dragging because of warped material?
David

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Re: More 16 Gauge issues

Post by otisa2007 » Wed Apr 13, 2022 5:16 pm

adbuch wrote:
Wed Apr 13, 2022 5:11 pm
otisa2007 wrote:
Wed Apr 13, 2022 5:09 pm
I am running the older powermax 45 which it will cut at the rated speed i keep it slowed down due to the height control I only have the basic plasmacam height control and most of my problems with 16 ga come from the tip dragging on the metal the biggest drawback to the slower cut speed is the dross and most of my 16ga cuts are artwork on straight line stuff like my ash pans for the fire pits i can run the faster speeds
Is your tip dragging because of warped material?
David
Yes the 16ga i get warps faster than the height control can keep up on intricate designs at high speeds

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Re: More 16 Gauge issues

Post by Andynorris » Wed Apr 13, 2022 6:07 pm

adbuch wrote:
Wed Apr 13, 2022 4:15 pm
Andynorris wrote:
Wed Apr 13, 2022 1:27 pm
Just curious adbuch. What machine are you using and there any known issues with using a Powermax 105 on thin gauge. I have heard that they are very voltage sensitive in relation to the THC.

Thanks
I am using my Hypertherm Powermax 85 for cutting 22 ga. steel on my Plamacam DHC2 table. I use the same settings and consumables (FineCuts) that I would use with my 45xp.
David

PS. As I mentioned previously, try using the 30 amp consumables for your machine. You will most likely have better results for thin material.
I Will try that adbuch, thanks for the advise.
Andy

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Re: More 16 Gauge issues

Post by adbuch » Wed Apr 13, 2022 6:43 pm

viewtopic.php?t=20454
powermax 30 consumables on 45 - 1.jpg
https://weldingweb.com/vbb/threads/6163 ... es-on-a-30
powermax 30 consumables on 45.jpg

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