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If you’re passionate about metal cutting or just keen to learn more, you’ve landed in the right place.
For over 38 years, Amber Steel has been at the forefront of metal cutting services, specializing in laser cutting, flame cutting, and plasma cutting. Our expertise has carved a niche in this cutting-edge industry, delivering precision and excellence across industrial projects big and small.
In our blog, we’ll share a mix of useful tips, innovative applications, our thoughts on sustainability in steel cutting, and more. Expect stories from the cutting floor, insights into how our processes can streamline projects across industries, and a few lessons we’ve learned along the way.
While we keep some of our trade secrets under wraps, this blog is designed to offer valuable nuggets of wisdom that you simply won't find anywhere else. Whether you’re a professional in the industry or someone fascinated by the possibilities of metal cutting, you'll find something of value here.
So, stick with us as we delve into the finer points of metal work. We’re glad to share our insights and lead discussions that matter to our industry.
How precision metal cutting propels the aerospace industry, from constructing lighter frames to enhancing aerodynamics.
The role of advanced metal cutting in automotive manufacturing, driving innovations in vehicle design and efficiency.
All about the robust and versatile process of flame cutting, ideal for tackling thicker metals with precision and ease.
Discover the art of crafting metal furniture, where cutting techniques meet design to create both functional and aesthetic pieces.
A behind-the-scenes look at the mechanics of metal cutting technologies and the science that makes them tick.
Laser cutting is where extreme precision meets efficiency, allowing for intricate designs and clean finishes.
The critical role of precise steel cutting in developing reliable and intricate medical devices.
How steel cutting supports the oil and gas industry with components that withstand extreme environments and pressures.
Known for its speed and versatility, plasma cutting slices through conductive metals with hot plasma.
Safety first! Tips and insights on maintaining a safe environment while handling powerful metal cutting equipment.
The backbone of construction, where steel fabrication and cutting technologies create frameworks that shape skylines.
Sustainability
A look at sustainability in metal cutting, focusing on practices that reduce waste and conserve energy to protect our planet.
Flame cutting, also known as oxyfuel cutting, dates to the early 19th century. This process was developed when French engineers Edmond Fouché and Charles Picard developed oxygen acetylene welding in the early 1900s. The process itself utilizes pure oxygen to produce a flame so hot it can melt the steel under the power of the torch.
But how is flame cutting used in modern day and what have we learned since its inception? Amber Steel experts will explain this and more in today’s blog about the history of flame cutting.
During the early 20th century, before the development of arc welding, the utilization of oxyacetylene was preferred due to its cutting capability for the majority of commercial materials ranging from carbon steel, iron, steel alloy, and more.
However, in recent times, flame cutting has been widely implemented as a preferred industrial cutting technology due to its efficiency and overall cutting effectiveness.
Flame cutting can cut materials up to 250 mm (about 9.84 in) using relatively cost-effective equipment, all with the process's capability being automated enough for larger-scale projects.
Flame cutting involves a process of cutting through metals such as steel by using a focused, high-intensity stream of oxygen and a fuel gas flame. The metal's surface is heated to a high temperature while a jet of pure oxygen is directed to the heated area. The oxygen then interacts with the metal, causing rapid oxidization that creates a precision cut.
The oxygen directed into the metal blows away the slag (a stony waste material that is extracted from metals during the process of smelting or refining ore), allowing the jet stream to penetrate through the metal as it cuts through.
As we mentioned, in 1903, Edmond Fouché and Charles Picard developed early oxygen-acetylene welding. Prior to this, welding had been used in several other forms, but generating enough heat to cause a melting reaction in metal that was also precise was an inconceivable concept for the time.
By utilizing acetylene, the French engineers discovered that they could create a flame that burned almost twice as hot as the average propane fire. This discovery resulted in the quick adoption of this early flame cutting process, although it would later be improved in the modern era.
Once the oxyacetylene torch was developed, its application in cutting metal was soon realized. By directing the flame onto the metal’s surface, the intensity of the heat would melt through the metal, and a stream of pure oxygen would blow away the molten metal – effectively creating a precision cut. This process would later be known as oxyfuel cutting or flame cutting.
Flame cutting was quickly applied to several different industries such as shipbuilding, manufacturing, and construction. Flame cutting during the early periods and even in modern times offered an inexpensive and portable means of cutting through quick metal plate and shapes, which were otherwise difficult to cut with traditional tools. The development of flame cutting offered a modern solution to a period-specific problem that would only improve with time.
Over the years, further advancements in materials and equipment have been developed to refine the flame cutting process. Different fuel gases and combinations have since been explored to increase flame cutting speeds and efficiencies. For example, CNC automation has been integrated into the flame cutting system to allow for more precise and automatic cuts.
This process allows for larger-scale and more complex projects.
While there are other advanced forms of cutting technology such as laser cutting and plasma cutting, flame cutting is still a relevant, effective process that is ideal for cutting thicker materials. As well, in comparison to plasma and laser cutting, flame cutting can be more economical.
It continues to have several modern-day applications across several industries, including structural steel fabrication and demolition.
Flame cutting as a practice is still used today, with advancements in technology making it a quicker and more precise process. Let’s explore how things have changed since the early implementation of flame cutting.
CNC flame cutting is performed with a CNC cutting machine that utilizes CNC technology to operate a flame cutting table along with a torch to cut through steel plates, sheets, and other metals. CNC flame cutting equipment is integrated into the machine and consists of the CNC unit, table, and flame torch, and utilizes flame cutting systems, drive systems, and CNC controls.
Basic Principle: CNC flame cutting uses an oxy-fuel torch mounted on a CNC machine. The torch heats the metal to its ignition temperature, and a stream of oxygen is then directed at the metal, causing it to react with the oxygen and burn. The burning metal is blown away from the kerf (cutting path) by the oxygen stream, resulting in a clean cut.
CNC Control System: The CNC system controls the movement of the cutting torch and the flow rates of the fuel gases (typically acetylene, propane, or natural gas) and oxygen. The cutting path is programmed into the CNC machine using CAD (Computer-Aided Design) software or directly through manual programming of coordinates.
To really understand the changes that have occurred in flame cutting history, you need to understand how technology has advanced in modern times. CNC flame cutting, for example, takes the base principle of flame cutting and applies new, modern-day technology to it to create a more automated and efficient process.
Before the actual cutting process begins, the desired shape/profile is designed ahead of time utilizing Computer Aided Design (CAD) software. The CAD file is converted into a format that is readable by the CNC machine, allowing it to interpret them to move the torch along the programmed cutting path to achieve the desired shape. This allows for very precise cutting and production.
Prior to cutting, the metal plate is prepared by cleaning it to ensure a smooth surface and removing any contaminants that could affect the cutting process. The plate is then secured on the CNC machine's cutting table.
Once the setup is complete and the CNC program is loaded, the cutting process begins. The CNC machine precisely controls the movement of the cutting torch along the programmed path. It adjusts the torch height and angle automatically to maintain consistent cutting parameters, such as cutting speed, preheat temperature, and oxygen flow.
CNC flame cutting offers several advantages. Here, we’ll explore some of those key advantages as we consider the technological advances of flame cutting history.
CNC flame cutting is extremely precise because it cuts according to a pre-programmed design. The machine eliminates most of the potential for human error and improves overall quality. The more precise the cuts are, the fewer mistakes are made, and the less likely material is wasted.
CNC flame cutting allows for increased cutting speeds when compared to manual flame cutting, which can help improve productivity. That doesn’t mean that handheld flame cutting is bad – it is still a highly efficient process, CNC flame cutting is simply faster.
With the high-tech capabilities of CNC flame cutting, complex shapes can be cut with key precision and accuracy due to the ability to input a design into the system. This could be more difficult to complete using more manual methods.
CNC flame cutting is commonly used in industries such as shipbuilding, heavy equipment manufacturing, structural steel fabrication, and metal artwork. It is particularly effective for cutting thick carbon steel plates (typically ranging from 5mm to 300mm or more), where other cutting methods like laser cutting or plasma cutting may be less economical.
However, each method has its own merits and can be affordable depending on the situation, so each should be considered based on the project and your personal needs.
The flame cutting process is generally ideal for situations where the surface of the material is made of milder steel or low alloy steel, and the thickness of the material you need to cut is more than 50 mm (2 inches). Flame cutting is favourable when the plasma's cut edge is not suitable or if you need something slightly more economical.
If you have any questions on whether you should go with flame cutting or other forms of fabrication, check in with the experts at Amber Steel. Our years of expertise can help you see what process is best suited for your needs.
Amber Steel keeps a substantial stock of high-quality steel materials to ensure fast fulfillment of our customers' delivery needs. Every finished product is backed by material certification and test reports, ensuring consistent quality across the board.
Whatever your fabrication needs, the experts at Amber Steel have what you need.
