Arc Keeps Going Out/sometimes just not piercing throught the metal

I’m having issue with cutting into 1/8" Aluminum with a Crossfire Pro. I use SheetCAM as my application. I am fully self taught, so I’m sure I made a few mistakes. Here is what my cuts are looking like.

I’m using a Razor Cut 45. Here is my settings below.
45Apms
65PSI

Here is my SheetCAM plasma settings that I use.
Kerf Width: 1.5mm
Feed Rate: 80ipm
Pierce Delay: 0.6s
Pierce Height: 3mm
Plunge Rate: 10ipm
Cut Height: 1.5mm
Pause at end of cut: 0.3s

I’ve successfully been able to cut 1/16" with the same settings except at 100ipm instead.

I would lengthen your pierce delay, start at 0.7 and go up till you get a good pierce.

Also, I think I would speed up the plunge rate to 50 ipm

Only adjust 1 parameter at a time so you know the results of each.

As @72Pony stated for your settings. Also up your air to 75PSI and turn off THC. If that works then you need to get the THC working properly.

Welcome to the forum.

1 Like

Can you post the G-Code I just want to see if some of the metric imperial conversions aren’t maybe messing with a setting.

Unfortunately increasing the plunge rate has only made the cut worse. I’ve also tried increasing the pierce delay but that doesn’t seem to be helping much. I’ve turned off the THC

Here is the Gcode. Because I’m a new user I cannot upload a file.
(v1.6-sc)
G90 G94
G17
G21 (Units: Metric)
H0
G0 X14.2678 Y14.2678

G92 Z0.
G38.2 Z-127.0 F2540.0
G38.4 Z12.7 F508.0
G92 Z0.0
G0 Z0.508 (IHS Backlash)
G92 Z0.0
G0 Z10.0 (Pierce Height)
M3
G4 P2
G1 Z1.5 F1905.0 (Cut Height)
H1
G2 X15.0 Y12.5 I-1.7678 J-1.7678 F1905.0
G2 X12.5 Y10.0 I-2.5 J0.0
G2 X10.0 Y12.5 I0.0 J2.5
G2 X12.5 Y15.0 I2.5 J0.0
G2 X14.2678 Y14.2678 I0.0 J-2.5
H0
M5
G4 P0.3
G0 Z25.4
G0 X25.75 Y25.0

G92 Z0.
G38.2 Z-127.0 F2540.0
G38.4 Z12.7 F508.0
G92 Z0.0
G0 Z0.508 (IHS Backlash)
G92 Z0.0
G0 Z3.5 (Pierce Height)
M3
G4 P2
G1 Z1.5 F1905.0 (Cut Height)
H1
G3 X25.0 Y25.75 I-0.75 J0.0 F1905.0
G1 X0.0
G3 X-0.75 Y25.0 I0.0 J-0.75
G1 Y0.0
G3 X0.0 Y-0.75 I0.75 J0.0
G1 X25.0
G3 X25.75 Y0.0 I0.0 J0.75
G1 Y25.0
M5 M30
(PS1905)

How high have you gone on the pierce delay?

Also, as @mechanic416 said most people using the RW45 report best results setting the air to 75 psi. You may have to remove the cover to adjust the internal regulator.

I’m at 2 seconds for pierce delay. And I’ve tried with 75psi

Why is your first pierce height 10mm? The second one looks correct at 3.5mm. Did you modify the post processor to give these different values for the first cut loop?

The pierce delay is 2, is that seconds or milliseconds?

My rw 45 cut chart for .125 aluminum shows 30 amps and 27 Imp or 686 mm. Even at 45 amps may be a little fast

2 seconds

I’ve reset my computer as well as the plasma cutter and that seemed to fix the weird pierce height issue.
(v1.6-sc)
G90 G94
G17
G21 (Units: Metric)
H0
G0 X14.2678 Y14.2678

G92 Z0.
G38.2 Z-127.0 F2540.0
G38.4 Z12.7 F508.0
G92 Z0.0
G0 Z0.508 (IHS Backlash)
G92 Z0.0
G0 Z4.0 (Pierce Height)
M3
G4 P1.5
G1 Z1.5 F1270.0 (Cut Height)
H1
G2 X15.0 Y12.5 I-1.7678 J-1.7678 F1905.0
G2 X12.5 Y10.0 I-2.5 J0.0
G2 X10.0 Y12.5 I0.0 J2.5
G2 X12.5 Y15.0 I2.5 J0.0
G2 X14.2678 Y14.2678 I0.0 J-2.5
H0
M5
G4 P0.3
G0 Z25.4
G0 X25.75 Y25.0

G92 Z0.
G38.2 Z-127.0 F2540.0
G38.4 Z12.7 F508.0
G92 Z0.0
G0 Z0.508 (IHS Backlash)
G92 Z0.0
G0 Z4.0 (Pierce Height)
M3
G4 P1.5
G1 Z1.5 F1270.0 (Cut Height)
H1
G3 X25.0 Y25.75 I-0.75 J0.0 F1905.0
G1 X0.0
G3 X-0.75 Y25.0 I0.0 J-0.75
G1 Y0.0
G3 X0.0 Y-0.75 I0.75 J0.0
G1 X25.0
G3 X25.75 Y0.0 I0.0 J0.75
G1 Y25.0
M5 M30
(PS1905)

However my cuts are only getting worse

Ran your code (1st post) on my machine. 45 Amps with a PrimeWeld Cut60. Ran ok with exception of the pierce height that @ds690 already mentioned and there is no lead-in or lead-out which made gouges in hole and top right corner. These parts are tiny, surprised it did that well on the hole (≈0.23"/5.8mm)

You may need to look at your setup, air supply and consumables.

think it might be an issue with the nozzle?

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What do your consumables look like? Does the arc look green? That’s an indication that the electrode is trashed.

it’s a little melted

The nozzle looks bad, but it’s hard to tell from that angle. The more important thing is the electrode that is under the nozzle.

1 Like

Here is a diagram of the consumables in your torch. Tips and electrodes need to be replaced the most often.

What amp rating does that nozzle have?Looks like your over amping it. 40 amp nozzle won’t last long at 50 amps and so on. Like 72pony said you must be at 75psi. 65 psi seems to low.

2 Likes

They are 45 amp tips and the one in the picture is totally wasted. So my guess is the electrode is bad also.

4 Likes