Systems and methods for multi-path gouging

1. A method for determining a plurality of operating parameters to process a workpiece to create a multi-pass gouging shape within the workpiece using a manufacturing processing system comprising a plasma arc gouging torch, the method comprising:

positioning a plasma arc gouging torch at a location relative to a workpiece;

determining a start point and an end point for each of a plurality of gouging paths and gouging layers based on the location and a gouge profile;

a. using the gouge profile to determine first operating parameters for the plasma arc gouging torch for a first gouging path of the plurality of gouging paths of a first gouging layer, the first operating parameters including a first torch angle between the torch and the workpiece, the torch angled in a direction of torch travel;

b. determining second operating parameters for the plasma arc gouging torch for a second gouging path of the plurality of gouging paths of the first gouging layer based at least on the gouge profile and the first gouging path, wherein the second operating parameters comprise a second torch angle between the torch and the workpiece and a lateral torch offset distance relative to the first gouging path;

c. using the first and second operating parameters to process the first gouging layer of the workpiece with the plasma arc gouging torch, and

d. repeating step (a) for a second gouging layer, thereby obtaining a desired multi-pass gouging shape.

2. The method of claim 1 , wherein the first gouging path and the second gouging path are located on substantially a same plane and are oriented substantially parallel to one another.

3. The method of claim 1 , wherein the first operating parameters comprise at least one of a first torch speed, a first torch angle, a first torch height, a first torch amperage, or a first torch pressure, and the second operating parameters comprise at least one of the second torch speed, a second torch angle, a second torch height, a second torch amperage, the torch offset, or a second torch pressure.

4. The method of claim 3 , wherein at least one of the second operating parameters are different than at least one of the first operating parameters.

5. The method of claim 3 , wherein the second torch speed of the second gouging path is greater than the first torch speed of the first gouging path.

6. The method of claim 5 , wherein the second torch speed of the second gouging path is about 5% greater than the first torch speed of the first gouging path.

7. The method of claim 5 , wherein the second torch speed of the second gouging path is between about 5% and 80% greater than the first torch speed of the first gouging path.

8. The method of claim 1 , further comprising:

determining third operating parameters for a third gouging path of the plurality of gouging paths based at least on the gouge profile, the first gouging path, and the second gouging path,

wherein a portion of the third gouging path is located at a depth below a depth of an initial layer of the gouge profile.

9. The method of claim 8 , wherein a third torch speed of the third gouging path is less than a first torch speed of the first gouging path and a second torch speed of the second gouging path.

10. The method of claim 8 , further comprising:

determining fourth operating parameters for a fourth gouging path of the plurality of gouging paths based at least on the gouge profile, the first gouging path, the second gouging path, and the third gouging path,

wherein the fourth gouging path is located at a depth of a last layer of the gouge profile.

11. The method of claim 10 , wherein a fourth torch speed of the fourth gouging path is greater than a third torch speed of the third gouging path.

12. A method for determining a plurality of operating parameters to process a workpiece to create a multi-pass gouging shape within the workpiece using a manufacturing processing system comprising a plasma arc gouging torch, the method comprising:

positioning a plasma arc gouging torch at a location relative to a workpiece;

calculating a start point and an end point for each of a plurality of gouging paths and gouging layers based on the location and a gouge profile;

a. using the gouge profile to determine first operating parameters for a first gouging path of the plurality of gouging paths of a first gouging layer, the first operating parameters including a first torch angle between the torch and the workpiece, the torch angled in a direction of torch travel;

b. initiating the plasma arc gouging torch with at least one of the first operating parameters;

c. determining second operating parameters for a second gouging path of the plurality of gouging paths for the first gouging layer based at least on the gouge profile and the first gouging path, wherein at least one of the second operating parameters are different than at least one of the first operating parameters and include a second torch angle between the torch and the workpiece and a lateral torch offset distance relative to the first gouging path;

d. initiating the plasma arc gouging torch with at least one of the second operating parameters, and

e. repeating steps (a) and (b) for a second gouging layer, thereby obtaining a desired multi-pass gouging shape.

13. The method of claim 12 , wherein the first operating parameters and the second operating parameters further comprise at least one of a torch speed, a torch angle, a torch height, a torch amperage, or a torch pressure.

14. The method of claim 13 , wherein the torch offset is more than 50% of a width of the first gouging path.

15. The method of claim 13 , wherein a second torch speed of the second gouging path is greater than a first torch speed of the first gouging path.

16. The method of claim 15 , wherein the second torch speed of the second gouging path is about 5% greater than the first torch speed of the first gouging path.

17. The method of claim 15 , wherein the second torch speed of the second gouging path is between about 5% and 80% greater than the first torch speed of the first gouging path.

18. The method of claim 12 , further comprising:

determining third operating parameters for a third gouging path of the plurality of gouging paths based at least on the gouge profile, the first gouging path, and the second gouging path,

wherein the third gouging path is located at a depth below a depth of an initial layer of the gouge profile.

19. The method of claim 18 , wherein a third torch speed of the third gouging path is less than a first torch speed of the first gouging path and a second torch speed of the second gouging path.

20. The method of claim 18 , further comprising:

determining fourth operating parameters for a fourth gouging path of the plurality of gouging paths based at least on the gouge profile, the first gouging path, the second gouging path, and the third gouging path,

wherein the fourth gouging path is located at a depth of a last layer of the gouge profile.

21. The method of claim 20 , wherein a fourth torch speed of the fourth gouging path is greater than a third torch speed of the third gouging path.

22. A method for determining a plurality of operating parameters to create a multi-pass gouging shape within a perimeter of a workpiece using a manufacturing processing system comprising a plasma arc gouging torch, the method comprising:

positioning a plasma arc gouging torch at a location relative to a workpiece;

determining a start point and an end point for a gouging path based on the location and a gouge profile;

using the gouge profile to determine a plurality of operating parameters for the gouging path, wherein the plurality of operating parameters comprises varying a lateral torch speed of the plasma arc gouging torch while performing a pass over the gouging path;

using at least one of the plurality of operating parameters to process the workpiece with the plasma arc gouging torch; and

varying the lateral torch speed of the plasma arc gouging torch based on a location of the torch relative to an edge of the gouge profile such that the lateral torch speed is reduced near a center of the gouge and increased near edges of the gouge, wherein the lateral torch speed is also a function of a depth of the gouge path at the location.

23. The method of claim 22 , wherein the plurality of operating parameters further comprises at least one of a torch angle, a torch height, a torch amperage, or a torch pressure.

24. The method of claim 22 , wherein an axial torch speed of the plasma arc gouging torch is constant.

25. The method of claim 24 , wherein a ratio of the lateral torch speed and the axial torch speed varies based on the location of the torch relative to the edge of the gouge profile.

26. The method of claim 25 , wherein the ratio of the lateral torch speed and the axial torch speed is a maximum ratio and a distance between the location of the torch and the edge of the gouge profile is a minimum distance.

27. The method of claim 26 , wherein the maximum ratio is about 4.

28. The method of claim 22 , wherein the lateral torch speed is based on a material removal rate.