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In the field of industrial pipeline processing, orbital pipe cutting machines are widely used in petroleum, chemical, electric power, natural gas, shipbuilding and other industries due to their high degree of automation, fast cutting efficiency and wide range of pipe diameters. However, some users will encounter a thorny problem in actual use - low cutting accuracy, large slit deviation, obvious cross-section burrs, uneven end face inclination and other phenomena frequently occur, which not only affects the subsequent welding quality, but also may lead to a decrease in the efficiency of the entire process.
So, what factors cause the low cutting accuracy of the orbital pipe cutting machine? This article will conduct a detailed analysis from multiple aspects such as the equipment itself, operating procedures, consumables selection, environmental factors, etc., and put forward corresponding solutions to help you improve cutting accuracy and achieve efficient and accurate pipeline processing.
1. Improper track installation or track deformation
The core of the orbital pipe cutting machine lies in the "track" guide system, and its accuracy directly affects the cutting quality.
1.1 Uneven track installation
If the track is not leveled during installation, it will cause the cutting machine to shake or deviate slightly during walking, resulting in deviations in the cutting line.
Solution suggestions:
Before installing the track, be sure to use a level to measure it comprehensively to ensure that all joints of the track are tightly connected and the track is straight as a whole without obvious height differences. At the same time, regularly check whether the track is loose or worn, and calibrate and reinforce it in time.
1.2 Problems with the material or structure of the track itself
Some low-quality tracks have problems of poor rigidity and easy deformation, especially when high-temperature cutting or heavy cutting equipment is walking, which is prone to micro-bending, affecting the guidance accuracy.
Solution suggestions:
Select tracks made of high-strength steel to ensure their load-bearing capacity and anti-deformation ability. For places with frequent use or harsh environment, it is recommended to use reinforced tracks and increase support points to avoid track sinking or skewing.
2. Poor stability of the equipment body
The track is only a guiding system, and the stability of the equipment body is also an important factor affecting cutting accuracy.
2.1 Loose structure of the cutting machine
With the extension of the use time, some mechanical connection parts inside the track-type cutting machine (such as the cutting head fixing seat, motor bearings, gear transmission mechanism, etc.) may become loose or worn, resulting in shaking or trajectory deviation during cutting.
Solution suggestions:
Regularly inspect the whole machine, focusing on checking the tightness of the connectors, whether the transmission parts are worn, whether the motor runs smoothly, etc. If there is looseness, it must be dealt with immediately to prevent the problem from expanding.
2.2 Unreasonable center of gravity distribution
Some equipment designs have the problem of center of gravity offset. When the equipment moves on the track, the center of gravity deviates from the central axis, resulting in unstable operation and affecting the cutting accuracy.
Solution suggestions:
When purchasing, priority should be given to equipment with reasonable center of gravity distribution and moderate chassis width. At the same time, during installation or movement, pay attention to keeping the equipment level and avoid tilting operation.
3. Improper setting of cutting parameters
Even if there is no problem with the hardware equipment, incorrect cutting parameters will also lead to substandard cutting quality.
3.1 Cutting speed is too fast or too slow
The cutting speed directly affects the flatness and verticality of the cut. Too fast speed can easily cause slag adhesion and uneven cut; too slow speed may cause problems such as expansion of the heat affected zone, pipe edge burning, and edge deformation.
Solution suggestions:
Set the appropriate cutting speed according to pipes of different materials and wall thicknesses. For example, the speeds required for carbon steel and stainless steel are different, and thick-walled pipes and thin-walled pipes are also different. It is recommended to refer to the equipment manual or the manufacturer's recommended parameters.
3.2 Improper settings of cutting flame or plasma power
The flame size or plasma current intensity is too low, and the cutting cannot be done through; too high will cause the edge to be over-melted, deformed, and affect verticality.
Solution suggestions:
Make sure to use the appropriate type of cutting nozzle, the appropriate flame angle and gas ratio. If it is plasma cutting, the appropriate current value needs to be matched according to the actual material thickness.
4. Angle error between the cutting head and the pipe
When cutting with a track-type cutting machine, the cutting head should be kept vertical to the pipe, otherwise the incision will be beveled, resulting in the inability to dock the interface or requiring a lot of post-processing.
4.1 The installation angle is not adjusted in place
Many operators ignore the angle adjustment of the cutting head before cutting and directly operate, resulting in a skewed cutting surface.
Solution suggestions:
After each installation or replacement of the cutting head, be sure to use an angle meter to calibrate the angle to ensure that it is perpendicular to the central axis of the pipe.
4.2 The pipe itself is not fixed properly
If the pipe rotates or shakes during the cutting process, it will also cause the cutting angle to change, affecting the verticality and shape accuracy of the cutting.
Solution suggestions:
Before cutting, the pipe must be firmly fixed to avoid movement during operation. For large pipes, special brackets or clamps can be used for auxiliary support.
5. Insufficient operator experience
Even the most advanced equipment requires professional operators to control and maintain it. Irregular operating behavior can easily affect the cutting accuracy.
5.1 Lack of understanding of equipment and operating errors
Some novice operators are not familiar with the functions of the track cutting machine, and blindly adjust the parameters when setting the operation interface, resulting in reduced cutting quality.
Solution suggestions:
Operators should receive professional training, be familiar with the setting logic of various parameters, the response methods of different materials, and regularly learn new technologies and new functions.
5.2 Neglecting daily maintenance
Daily cleaning and lubrication are not in place, the service life of the equipment is shortened and the accuracy is reduced. For example, dust or iron filings attached to the slide rail may cause unstable operation.
Solution suggestions:
Develop a regular maintenance plan, especially for rail cleaning, transmission lubrication, nozzle replacement, flame calibration, etc., to ensure that the equipment is always in the best working condition.
6. External environmental interference factors
In addition to equipment and human factors, the external environment may also indirectly affect
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