High Definition Plasma Cutting System

 

Jaydeep Steels High-Definition Plasma Cutting System with Plasma Beveling Precision High-Definition Cutting Combined With State-of-the-Art Plasma Edge Beveling Unsurpassed Flexibility in Processed Stainless and Nickel Alloy Plate Parts

Once again, Jaydeep Steels is at the forefront of the implementation of plate processing equipment for the production of Stainless Steel and Nickel Alloy Plate Parts. We’ve added a state-of-the-art High-Definition Plasma Cutter capable of cutting high definition up to 2.0″ (50.8mm). The machine is also equipped with a Plasma Edge Beveler that can bevel parts through 3.0″ (76.mm). Our high-definition cutting system combines Y-axis linear ways with pitch line rack and pinion drives to provide the industry’s smoothest cut edge and precise holes. Wider end trucks with a maximum guide roller spread further stabilize the X-axis motion for the ultimate cut edge performance.

The new bevel cutting head, combined with a sophisticated software package, provides the most precise plasma cut edges available in the market today. The system’s unique design keeps the critical components away from the cutting torch, minimizing the risk of damage to the torch by slag, heat, and unwanted contact.

The plasma beveled head is capable of accurate beveled parts on any angle from +52 degrees to -52 degrees. Torch height is automatically controlled to an accuracy of +/- .006″ (15mm), so part integrity is maintained throughout the cut. Corner loop size down to 0.394″ (10mm) can be achieved without requiring start/stop commands. The result is accurate parts with square corners and minimal scrap up to 3.0″ (76.2mm) thick.

 

Thickness Range Conventional Plasma	3/16″ to 6.0 (4.8mm to 152.4mm)
Thickness Range High Definition	3/16″ to 2.0 (4.8mm to 50.8mm)
Thickness Range Bevel Cut	3/16″ to 3.0 (4.8mm to 76.2mm)
Bevel Range	+/- 52 degrees

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Plasma Beveling

 

Plasma beveling enables us to cut your parts to size and bevel the edges in one step. This cuts your manufacturing costs by eliminating or reducing downstream processing.

Most shapes can be beveled, including rectangles, circles, and parts created in a CAD program. Beveling can be performed on plate up to 3.0″ (76.2mm) thick, plus or minus 52 degrees, knife edge or with a land.

Abrasive Waterjet Cutting

 

At Jaydeep Steels we are committed to providing our customers with the most efficient and cost-effective methods of cutting Stainless Steel and Nickel Alloy Plate and plate products. In addition to our already diverse capabilities of plate processing, we are now offering multiple abrasive waterjets cutting systems to address your cutting needs. Our two WMC Series machines feature four cutting heads, integrated abrasive removal and recycling systems, WindowsT-based PC machine control and programming, and 60,000 psi pumps.

Jaydeep Steels abrasive waterjet cutting system can provide near-net shapes and intricate parts cut to the accuracy levels and close tolerances our customers require. Secondary finishing can now be minimized if not totally eliminated.

5-Axis Abrasive Waterjet Cutting

 

Jaydeep Steels latest addition to our state-of-the-art plate processing capabilities is our new Jet Edge EDGE X-5 five-axis abrasive waterjet cutting system.

It is capable of processing your most challenging three-dimensional cutting requirements. This machine enables us to offer you cost-effective contour bevel parts, chamfer holes, and weld bevels including K-Bevels.

Machine cut Rings & Discs

 

Our “specialty of the house.” Machined finishes are available at virtually the same cost as plasma cutting. Our rings and discs are machined to a tolerance of +1/16″ – .000″ on the O.D. and +.000″ – 1/16″ on the I.D. to give you a smoother edge with better concentricity than a plasma cut edge. In addition, you have no heat affected zone, which increases your tool life. We can turn up to 124″ (3150mm) OD, and face the surface of one or both sides to any special thickness or RMS finish. All of this means a lower ultimate “cost in use” to you.

With our unparalleled in-house processing capabilities, nearly any machined configuration is readily available. We can provide bevels, grooves or fine surface and edge finishes that you need.

Bandsaw Cutting

 

Bandsaw cutting provides a better edge quality than plasma cutting, with no heat-affected zone on the edges. Ideal for rectangular plate and bars cut from the plate from .250″ (6.3mm) thick to 6.0″ (152.4mm) thick; up to a maximum cut plate size of 124″ (3149.6mm) wide by 274″ (6959.6mm) long. Tolerances of +.125″ to -0″ on the width and length of the part can be achieved.

The Center was designed to process our largest full-size plates. As a result, we can provide a cut piece as large as 124″ wide and 274″ long. Additionally, the saws can cut narrow bars. This is especially useful for supplying bars cut from the plate for non-standard bar sizes and types.

Drilling (Tubesheet & Baffle), Tapping, Counterboring

 

Our proprietary research and development in drilling technology, combined with our state-of-the-art automatic indexing drilling equipment, result in a very low cost per drilled hole.

Standard bolt-hole patterns can be drilled and shipped in the same turnaround time as machined ring or disc blanks. We also can provide thread tapping and additional counterboring when required.

Milling

 

Need a special edge finished with close tolerances on a rectangular plate? Jaydeep Steels can do this on our special heavy-duty milling machines.

Need the same edge finishes on shapes and configurations? Jaydeep Steels can do contour milling on our sophisticated three axes, double column, vertical machining center. Edge beveling is also available.

Polishing

 

At Jaydeep Steels, we’re highly experienced in polishing stainless and nickel alloy plate and can provide a standard #4 finish or a 5 RMS maximum when requested. This can be done on all shapes.

Flattening

 

Commercial mill flatness tolerances for stainless steel plate and nickel alloy plate don’t meet the requirements of most customers today. At Jaydeep Steels, we do much better. Nearly every plate product we ship is individually flattened prior to shipping –at no additional cost to you. When your flatness requirement is especially critical, we have capabilities of flattening stainless steel plate to within .0625″ (1.6mm), based on the thickness and size of the piece. Flattening tube sheet blanks is Jaydeep Steels specialty.

Rolled & Welded Rings

 

Jaydeep Steels rolling and welding processes economically give you the large diameter rings you need by eliminating the yield loss of standard plate rings.

We can cut stainless and nickel alloy bars and roll them into easy-way or hard-way rings, within full ASME compliance, including code welding and x-ray.

RESEARCH & DEVELOPMENT

 

Our innovation and process-focused team constantly challenges our existing product portfolio. The team and develops new products and upgrades existing products to benefit our customers. We use the concept of “Design for Six Sigma” as a platform for Product development and follow a well laid out procedure for all our developments. Our expert Techno-commercial team always keeps the end user in mind and works closely with customer for their customized product offerings.

PRODUCT DEVELOPMENT PROCESS

 

Analytical Formulations

 

Using the basic laws of physics and hydraulics, we use analytical formulas, wherever applicable, for a basic design formulation. This helps us design the product from First Principles. Our team refers to the latest published papers and standards during the process.

 

3D & 2D Modelling

 

After these calculations, we create options through Solid Models via 2D and 3D design packages which:

 

The models are then validated by our manufacturing experts.

Finite Element Modelling & Analysis

 

 

Manufacturing

 

 

Final Testing