How to extend the life of a single carbon rod by optimizing the carbon rod use angle or current parameters?

How to extend the life of a single carbon rod by optimizing the carbon rod use angle or current parameters?

Here are some ways to extend the life of a single carbon rod by optimizing the carbon rod use angle or current parameters:

Optimize the use angle

Maintain a suitable tilt angle: In operations such as carbon arc gouging, the carbon rod and the workpiece surface should usually be maintained at a tilt angle of 45° - 60°. This angle range allows the arc to burn stably, the heat is concentrated in the gouging area, and unnecessary loss at the end of the carbon rod is reduced. If the angle is too large, the arc will disperse, and the end of the carbon rod will be heated unevenly, which is easy to cause local overheating and increased loss; if the angle is too small, it may cause molten iron to flow back, contaminate the carbon rod, and shorten its service life.

Avoid direct contact between the carbon rod and the workpiece: During operation, the carbon rod should be kept at an appropriate distance from the workpiece, generally 3 - 5mm. If the carbon rod is in direct contact with the workpiece, it will cause a short circuit, generate a large current instantly, and cause the end of the carbon rod to heat up and melt rapidly, seriously shortening the life of the carbon rod. At the same time, it may also damage the surface of the workpiece.

Adjust the angle according to the processing direction: When planing in a straight line, the angle of the carbon rod should remain stable; when planing at a curve or corner, the angle of the carbon rod needs to be adjusted appropriately according to the radius and direction of the curve to ensure that the arc can act evenly on the workpiece and avoid accelerated wear of the carbon rod due to uneven local force or arc offset.

Optimize current parameters

Choose the appropriate current value: Choose the appropriate current according to the diameter and material of the carbon rod and the thickness and material of the workpiece. Generally speaking, for carbon rods with smaller diameters, a smaller current should be used to prevent the carbon rod from overheating and burning. For example, for a carbon rod with a diameter of 6mm, when planing low-carbon steel, the current can be selected between 150-200A. If the current is too large, the carbon rod will be consumed quickly and may even be burned out in a short time; if the current is too small, the planing efficiency will be low and the arc will be unstable, which will also affect the service life of the carbon rod.

Stable current output: Use a stable power supply to avoid current fluctuations or instantaneous peaks. The instability of the current will cause uneven heat generation at the end of the carbon rod, resulting in local overheating of the carbon rod and accelerated loss. The stable output of current can be ensured by installing a voltage stabilizer or using a reliable power supply device.

Reasonably control the arc starting and arc ending currents: When starting the arc, a smaller current should be used, and then gradually adjusted to the normal working current after the arc is stable. When ending the arc, the current should also be gradually reduced before the power supply is cut off. This can reduce the impact of the arc on the end of the carbon rod, avoid damage to the end of the carbon rod due to instantaneous high temperature and strong current, and extend the service life of the carbon rod.