ESAB Squarecut Technology doubles cut speed, quality and hole cyclindricity in automated plasma applications

​Building on the success of its DMX Automated Plasma Beveller, ESAB has launched SquareCut Technology to further improve the productivity of automated plasma cutting operations.

ESAB said SquareCut Technology tilts the torch to compensate for the 1- to 3-degree edge angle inherent in high-precision plasma cutting to provide three distinct benefits:

  • A high-speed mode cuts up to two times faster without increasing bevel angle.
  • A quality mode creates a cut surface with a 0 to 1 degree bevel.
  • Improved enhanced hole technology cuts smaller holes with better cylindricity.

SquareCut Technology works with ESAB’s Columbus CAD/CAM software, Vision T5 CNC, the DMX 5-axis beveller and iSeries high-precision power source. It works at cutting outputs from 100 to 400 amps when cutting mild steel plate from 6 to 40mm thick.

SquareCut integrates all bevel compensations into the CNC. The technology simplifies making square cuts and allows any fine tuning to be done quickly and easily at the machine.

“SquareCut Technology increases productivity significantly,” said Steve Zlotnicki, global product manager, ESAB Cutting Systems. “Using the high-speed mode, an ESAB plasma system can cut faster than any competitive system. It’s the fastest, easiest and most intelligent way to increase plasma cutting profitability.”

As an example, standard-precision technology cuts 12mm steel at maximum of 200 amps and at speeds of about 2,690mm/min. Even if a user had a 400-amp system, trying to cut at higher outputs to improve travel speed would increase edge angle to 4 or 6 degrees, and the cut surface could then require an unacceptable amount of grinding or milling for a flush fit.

“SquareCut Technology lets you cut 12 mm steel all the way up to 400 Amps at 4,700mm/min — which is 75 percent faster than usual — while maintaining an acceptable bevel angle,” added Zlotnicki. “From thin to thick plate, SquareCut Technology enables users to cut at the maximum amperage of their system.”

In applications where the squarest edge possible provides more value than faster cutting speeds, users can choose SquareCut Technology’s quality mode. Cutting speeds will be slower than in high-speed mode, but edge angle will be in the range of 0 to 1 degrees.

In addition to plate edges, SquareCut Technology further improves ESAB’s enhanced hole technology by using the tilting capability of the DMX to improve hole cylindricity. A “bolt-ready” hole can eliminate post-cut drilling or reaming. With SquareCut, some holes can be cut even smaller than a 1:1 diameter-to-thickness ratio.

SquareCut Technology is complemented by ESAB’s SmartBevel Technology, which ESAB released with the introduction of the DMX automated plasma beveller in 2017. SmartBevel includes beveling data and all geometric compensations necessary to cut V, X, Y, and K bevels on mild steel from 6 to 50mm thick.

“ESAB cutting automation systems with a DMX bevel head enable user to expand the capabilities of their cutting table,” said Zlotnicki. “By bringing parts closer to their finished state, we help users reduce cycle, minimise part handling and reduce the number of people required to complete an assembly.”