Research on underwater flux cored arc cutting mechanism based on simulation of kerf formation

As an efficient underwater cutting method, flux cored arc cutting is not clear in its mechanism because it is difficult to directly observe the process. In this paper, we studied the mechanism of flux cored arc cutting in air first. The impact of cutting parameters was studied by cutting workpiece’s edge and observing it with a high-speed camera system. Secondly, a sandwich structure was designed to observe the underwater cutting process. The characteristics of air and underwater cutting were analyzed and compared, and it showed that the arc moved up and down while moving forward with the cutting torch in both circumstances. Based on the arc movement characteristics and the underwater circumstance, a numerical simulation of the underwater cutting process was conducted. The simulation results showed that different cutting parameters led to different cutting mode and kerf forming. The numerical results of temperature distribution and kerf shape were consistent to the experimental data, which revealed the cutting mechanism. This work is significant for further process optimization and cutting automation.