OPTIMIZATION OF PROCESS

PARAMETERS IN PLASMA ARC

CUTTING
 CHAPTER-1
INTRODUCTION
 INTRODUCTION
PLASMA:
The first three states of matter are solid, liquid and gas. For the most
commonly known substance, water, these states are ice, water and steam. If you
add heat energy, the ice will change from a solid to a liquid, and if more heat is
added, it will change to a gas (steam). When substantial heat is added to a gas, it
will change from gas to plasma, the fourth state of matter.
Definition of Plasma:
Plasma is an electrically conductive gas. The ionisation of gases causes the
creation of free electrons and positive ions among the gas atoms. When this
occurs, the gas becomes electrically conductive with current carrying
capabilities. Thus, it becomes a plasma.
Plasma in Nature:
One example of plasma, as seen in nature, is lightning. Just like a plasma torch,
the lightning moves electricity from one place to another.
In lightning, gases in the air are the ionisation gases.
Key Learning Points:
 Define what Plasma is
 Identify how Plasma Arc cutting works
 Identify component parts of a plasma cutting torch
Plasma Arc Cutting:
 Accurate cuts can be made in stainless steel and non-ferrous metals such as
aluminium by plasma arc cutting.

 The cuts are made by a high temperature, high velocity gas jet generated by
constricting an arc between a tungsten electrode and the component.
 The heat from the arc melts the metal and the gas jet removes the molten
metal from the cut.
 The arc operates in an inert inner shield, whilst an outer shield provides
protection for the cut surface.
 Argon, helium, nitrogen and mixtures of these gases are used for both the
inner and outer shields.
 The cutting is accompanied by a high noise level which can be reduced by
operating the torch under water.

As for other arc processes plus there is a danger of severe electric shock from the
high open circuit voltage, up to 400 V for cutting. Dangerous fumes and noxious
gases are formed when using nitrogen mixtures so it is important to have adequate
fume extraction. The intense arc requires a darker shade of filter glass, at least 16
EW (BS 697). Intense high-frequency noise is possible when cutting, especially
with non-transferred arcs, of levels 110 dB which requires ear muff protection.
Component Parts of a Plasma Arc Torch:

C.W. = Cooling water, nozzle and electrode may be water cooled

P = Plasma gas varies with different materials.
S.G. = Auxiliary shielding gas, usually Argon + 1 to 15% H2
T.E. = Tungsten electrode 60°
O.S.R. = Outer shielding ceramic to prevent double arcing
R = Resistance limiting pilot arc current (non-transferred)
E.S.B. = Electrode set back distance
N.C. = Nozzle constriction
C.O. = Orifice constriction improves velocity
2.5 mm dia., 250 amps max.,
3.00 mm dia., 350 amps max.
S.0. = Stand-off distance approx. 6mm
M.P. = Multi-ports shape the arc plasma and allow increased welding speed
H.F. = High-frequency discharge ignites the arc
N. = Copper Nozzle

Plasma (Cutting) Gas Selection:

 Selecting the proper gas for the material you are cutting is critical to get
a quality cut.
Functions of gas in Plasma Arc cutting:
 Plasma gas is also called the cutting gas. This is the gas that is ionised in the
plasma process and exits through the nozzle orifice.
Examples of plasma gas are:
 Air
 Oxygen
 Nitrogen
 Argon-Hydrogen
Selecting the Correct Gas:
The cutting gas selected depends on the speeds and quality of cut desired.
Several cutting gases can be used in a plasma system to improve cut quality and
speed. Nitrogen is widely used because it is relatively inexpensive and can be
used on many materials and thicknesses. Special mixtures of argon and
hydrogen can improve cutting speed and quality on thicker metals and those
other than carbon steels. Oxygen is used in combination with other gases to
improve cut quality by increasing heat, improving cutting speed, and/or
reducing power requirements. Compressed shop air is popular for many
applications because it is inexpensive and provides good quality cuts on
thicknesses under 25mm, especially on carbon steels.
Gas quality is critical for the proper operation of plasma arc cutting systems
and optimal cut quality. Any contaminates can cause misfiring, poor cut quality
or poor consumable life. Contaminates can be: gas impurities, moisture, dirt,
piping system contaminates or improper gases (i.e. Air in O2 systems-leaks, not
following proper purge procedures when changing gas).

Aluminium and stainless steels require non-oxidising gases for good cutting
results in both thin and thick sections. Argon/hydrogen mixtures permit good
cuts and high cutting rates because the hydrogen increases the arc voltage and
thermal conductivity of the mixture. Parallel kerfs, little dross, oxide-free cut
faces and minimal fumes result from the use of A/H2 mixtures.
Argon/Hydrogen/Nitrogen or A/N2 mixtures are used when machine cutting,
but nitrogen is not recommended for hand cutting due to the formation of
poisonous oxides of nitrogen. Higher cutting speeds are possible with this
cheaper mixture with little loss of quality. The increase in cutting efficiency is
probably derived from the greater anodic voltage drop associated with the
nitrogen gas.
When inert gases such as argon are used, the heat is derived from the electrical
energy of the arc. Carbon steels require an oxidising gas for the best results; the
exothermic iron-oxygen reaction provides additional heat at the cutting point
and so reduces the amount of electric power required. Air has proved to be a
most efficient gas.
Cutting Speeds for Plasma Arc Cutting:
This should be as high as possible for economic reasons provided a narrow
kerf and a clean cut at top and bottom edges are produced. For a given electric
power and gas mixture, there is an optimum speed range for each type and
thickness of material. Excess speed causes a decreased kerf width with an
increased bevel but current intensity is the main factor determining kerf width.
For manual control and complicated machine cuts 1 m/min is a reasonable
speed. In general speeds of several metres/min are used for straight line and
trimming cuts.

Material Thickness Thickness Cutting Gas

mm mm speed
Mm/min
Aluminium 1.5 40 1200 A/H2
5.0 50 1500 A/H2
12.0 400 3750 A/H2
25.0 400 1250 A/H2
Stainless steel 2 50 1600 A/H2
18/8
5 100 2000 A/H2
12 380 1500 A/H2
25 500 625 A/H2

Depth of Cut for Plasma Arc Cutting:

Plasma cutting power sources are rated on their cutting ability and amperage.
Therefore, for cut depths up to 6mm thick material, a low amperage plasma
cutter will suffice. For cut depths up to 12mm thick a higher amperage
machine will be required. Even though a smaller machine may be able to cut
through a given thickness of metal, it may not produce a quality cut. Instead,
you may get a sever cut which barely makes it through the plate and leaves
behind dross or slag. Every unit has an optimal range of thickness -- make sure
it matches up with what you need. In general, a 6mm machine has
approximately 25 amps of output, a 12mm machine has a 50-60 amp output
while a 18mm to 25mm machine has 80 amps output.

Safety Precautions:
The safety precautions to be observed for Plasma Arc cutting are similar for
other thermal processes with following clarifications:
Fire Prevention:
 Be sure the area is safe before doing any cutting.
 Keep a fire extinguisher nearby.
 Remove all flammables within 35 feet (10 m) of the cutting area.
 Quench hot metal or allow it to cool before handling or before letting
it touch combustible materials.
 Never cut containers with potentially flammable materials inside - they
must be emptied and properly cleaned first.
 Ventilate potentially flammable atmospheres before cutting.
 When cutting with oxygen as the plasma gas, an exhaust ventilation
system is required.

Toxic Fumes Produced by Plasma Cutting:

Cutting can produce toxic fumes and gases that deplete oxygen and cause
injury or death.
  Keep the cutting area well ventilated or use an approved air-supplied
respirator.
 Do not cut in locations near degreasing, cleaning or spraying
operations. The vapours from certain chlorinated solvents decompose
to form phosgene gas when exposed to ultraviolet radiation.
 Do not cut metal coated or containing toxic materials, such as zinc
(galvanised), lead, cadmium or beryllium, unless the area is well
ventilated and the operator wears an air-supplied respirator. The
coatings and any metals containing these elements can produce toxic
fumes when cut.
 Never cut containers with potentially toxic materials inside - they must
be emptied and property cleaned first.
 This product, when used for welding or cutting, produces fumes or
gases which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer.

Compressed Gas Equipment Safety:

 Never lubricate cylinder valves or regulators with oil or grease.
 Use only correct gas cylinders, regulators, hoses and fittings designed
for the specific application.
 Maintain all compressed gas equipment and associated parts in good
condition.
 Label and colour-code all gas hoses to identify the type of gas in each
hose. Consult applicable national or local codes.
Gas Cylinders Can Explode If Damaged:
Gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode.
  Handle and use compressed gas cylinders in accordance with applicable
national or local codes.
 Never use a cylinder that is not upright and secured in place.
 Keep the protective cap in place over valve except when the cylinder is
in use or connected for use.
 Never allow electrical contact between the plasma arc and a cylinder.
 Never expose cylinders to excessive heat, sparks, slag or open flame.
 Never use a hammer, wrench or other tool to open a stuck cylinder
valve.
Noise Can Damage Hearing:
Prolonged exposure to noise from cutting or gouging can damage hearing.
 Use approved ear protection when using plasma system.
 Warn others nearby about the noise hazard.
Pacemaker and Hearing Aid Operation:
Pacemaker and hearing aid operation can be affected by magnetic fields
from high currents. Pacemaker and hearing aid wearers should consult a doctor
before going near any plasma arc cutting and gouging operations.
To reduce magnetic field hazards:
 Keep both the work cable and the torch lead to one side, away from
your body.
 Route the torch leads as close as possible to the work cable.
 Do not wrap or drape the torch lead or work cable around your body.
 Keep as far away from the power supply as possible.
TAGUCHI DESIGN OVERVIEW:
Dr. Genichi Taguchi is regarded as the foremost proponent of robust parameter
design, which is an engineering method for product or process design that focuses
on minimizing variation and/or sensitivity to noise. When used properly, Taguchi
designs provide a powerful and efficient method for designing products that
operate consistently and optimally over a variety of conditions.
In robust parameter design, the primary goal is to find factor settings that minimize
response variation, while adjusting (or keeping) the process on target. After we
determine which factors affect variation, we can try to find settings for controllable
factors that will either reduce the variation, make the product insensitive to
changes in uncontrollable (noise) factors, or both. A process designed with this
goal will produce more consistent output. A product designed with this goal will
deliver more consistent performance regardless of the environment in which it is
used.
Engineering knowledge should guide the selection of factors and responses.
When interactions among control factors are likely or not well understood, we
should choose a design that is capable of estimating those interactions. Minitab can
help us to select a Taguchi design that does not confound interactions of interest
with each other or with main effects.
Noise factors for the outer array should also be carefully selected and may require
preliminary experimentation. The noise levels selected should reflect the range of
conditions under which the response variable should remain robust. Robust
parameter design uses Taguchi designs (orthogonal arrays), which allow us to
analyze many factors with few runs. Taguchi designs are balanced, that is, no
factor is weighted more or less in an experiment, thus allowing factors to be
analyzed independently of each other [18].
Minitab provides both static and dynamic response experiments.
• In a static response experiment, the quality characteristic of interest has a fixed
level.
• In a dynamic response experiment, the quality characteristic operates over a range
of values and the goal is to improve the relationship between an input signal and an
output response.
An example of a dynamic response experiment is an automotive acceleration
experiment where the input signal is the amount of pressure on the gas pedal and
the output response is vehicle speed. We can create a dynamic response experiment
by adding a signal factor to a design − see Creating a dynamic response
experiment. The goal of robust experimentation is to find an optimal combination
of control factor settings that achieve robustness against (insensitivity to) noise
factors. Minitab calculates response tables, linear model results, and generates
main effects and interaction plots for:
• signal-to-noise ratios (S/N ratios, which provide a measure of robustness) vs. the
control factors
• means (static design) or slopes (dynamic design) vs. the control factors
• standard deviations vs. the control factors
• natural log of the standard deviations vs. the control factors
Use the results and plots to determine what factors and interactions are important
and evaluate how they affect responses. To get a complete understanding of factor
effects it is advisable to evaluate S/N ratios, means (static design), slopes (dynamic
design),and standard deviations [18].
Surface Roughness Tester:
There are five steps to measure the surface roughness of specimens. Firstly, clamp
the work piece of project use a clamping in the machine. And then, setting a prop
of axis likes up and down, right or left direction. After finish setting, can start
measured a work piece. Lastly, a data value for roughness can print out after finish
measured.
The surface roughness tester (FORM TALY SURF) used in this work, with the
following specifications:
Manufacturer: Taylor Hobson, U.K,
Travelling length: 01mm-50mm,
Force: 4mN,
Stylus: Diamond 2μm tip radius,
Resolution: 16nm/1.0mm,
Software: Form ultra software
MATERIAL REMOVAL RATE:
The material removal rate, MRR, can be defined as the volume of material
removed
divided by the machining time. Material Removal Rate (MRR) is defined by:
MRR = WRW/T [g/min]
Where,
WRW: workpiece removal weight (g)
T: cutting time(s)
WRW is the weight different between before and after work piece cutting. The
volume different can be calculated when information regarding material density
available. The relation between WRW and WRV is given as follow:
WRV = WRW/ρ
Where,
ρ : Work piece density (g/ mm3)
The density of the Nickel-Base Alloys is 8 g/cm3 or 0.008g/mm3.

Various Input parameters:

 Voltage
 Current Flow Rate
 Arc Gap
 Kerf (width of cut)
 Cutting Speed
 Material Type and Thickness
 Cutting gas Pressure

DESIGN OF EXPERIMENTS (DOE):

Design of Experiments (DOE) is a powerful statistical technique introduced by
R.A.
fisher in England in 1920s to study the effect of multiple variables simultaneously
DOE can highly effective when:
a). Optimize product and process design , study the effect of multiple factor on
process.
b). Study the influence of individual factors on the performance and determine
which factor has more influence, and which one has less. It can also find which
factor should have higher tolerance and which tolerance should be relaxed.
In industry, designed experiments can be used to systematically investigate the
process or product variables that influence product quality. After you identify the
process conditions and product components that influence product quality, you can
direct improvement efforts to enhance a product's manufacturability, reliability,
quality, and field performance.
Because resources are limited, it is very important to get the most information from
each experiment you perform. Well designed experiments can produce
significantly
more information and often require fewer runs than haphazard or unplanned
experiments. In addition, a well-designed experiment will ensure that you can
evaluate the effects that you have identified as important [20].
.
Designed experiments are often carried out in four phases:
a) Planning,
b) Screening (also called process characterization),
c) Optimization, and
d) Verification.
Taguchi methods are most recent additions of tool kit design process for
manufacturing engineers and quality assurance experts. In contrast to stastical
process control which attempt to control the factors that adversely affect the
quality
of production. The significance of beginning quality assurance with an improved
process or product design is not difficult to gauge. Taguchi method systematically
reveals the complex cause and effect relationship between design parameter and
performance.
These lead to building quality performance into process and product before actual
production begins .Taguchi method have rapidly attained prominence because
wherever they have been applied, they lead to the major reductions into process
and
products before actual production begins .The foundation of quality depend upon
two premises :
1. Society incurs a loss any time the performance of product is not on target.
2. Product and process design require a systematic development, progressing
stepwise through system design, parametric design and finally tolerance design.
The first point suggests that whenever the performance of a product deviates from
its target performance, society suffer loss. Such a loss has two components: The
manufacture incurs a loss when he repairs or rectified return or rejected product.
The second point aims at quality engineering, a discipline that aims at engineering
not only function but also quality performance into products and process .
The following seven points highlight the distinguish feature of Taguchi’s approach
which aimed at assuring quality:
1. Taguchi defined the term quality as the deviation from on target performance
which
appears to be first paradox. According to him the quality of a manufactured
product
is the total loss generated by that product to the society from the time it is shipped.
2. In a competitive economy continuous improvement (CQI) and cost reduction are
necessary.
3. A CQI programmed include continuous reduction in the variation of product
performance characteristic in their target values.
4. Customer loss attribute to the product performance variation is often
proportional
to the square of the deviation performance characteristic from its target value.
5. The finally quality and cost of a product manufactured depends primarily on the
engineering design of the product and its manufacturing process.
6. Variation in the product depends primarily on the engineering design of the
product and its manufacturing process.
7. Statically planned experiments can efficiently and reliably identify the settings
of the product and process parameters that reduce performance variation.

SIGNIFICANCE OF FINDINGS:
From the thesis writing, it is important to get the best setting of Plasma Arc
Cutting machine to maximize the Metal Removal Rate (MRR) and minimize the
Surface Roughness (Ra) response during the advance material cutting process. From
the result of the experiments using the Taguchi Method by Minitab 15 Software for
Design of Experiments, the best combination of factors can be obtained, and the
conclusions for the works that have been carried out can be determined.

OBJECTIVES:
This project was developed to study about the plasma arc cutting parameter in
smooth cutting using straight polarity process. The main purposes of this project
are
listed below:
a) To study about the influence of Plasma Arc Cutting Parameters on Stainless
Steel.
b) To design a series of experiment using the help of Design of Experiments
(DOE)
layout in order to study about Plasma Arc Cutting (PAC).
c) To study about the best combination of solution for maximizing the Material
Removal Rate (MRR) and for minimizing the Surface Roughness (μm) with
Taguchi Method .
SCOPE:
Generally these projects will be developing within the scopes below:
1. This project focuses on the optimization of cutting parameters of Plasma Arc
Cutting (PAC).
2. The material used to cut was Stainless Steel of specification ASTM A240
TP316 L.
3. Design of Experiments (DOE) layout will be used for testing and analyzing
with Taguchi Method .
4. All of data was analyzed by using Minitab 15 Software to produce the best
combination setting in plasma cutting for Stainless Steel.
5. The machine used will Silverin CNC Plasma Cutting Machine with Sharp line,
Bombay make Burney 10 LCD to perform the machining operation.
 CHAPTER-2
LITERATURE REVIEW
LITERATURE REVIEW:
Plasma cutting is a process that is used to cut steel and other metals (or sometimes
other materials) using a plasma torch. In this process, an inert gas (Argon) is blown
at
high speed out of a nozzle and at the same time an electrical arc is formed through
that gas from the nozzle to the surface being cut, turning some of that gas to
plasma.
The plasma is sufficiently hot to melt the metal being cut and moves sufficiently
fast
to blow molten metal away from the cut. Plasma can also be used for plasma arc
welding and other applications.
Plasma is typically an ionized gas. Plasma is considered to be a distinct state of
matter, apart from gases, because of its unique properties. Ionized refers to
presence
of one or more free electrons, which are not bound to an atom or molecule. The
free
electric charges make the plasma electrically conductive so that it responds
strongly
to electromagnetic fields.
The Arc type uses a two cycle approach to producing plasma. First, a high-voltage,
low current circuit is used to initialize a very small high intensity spark within the
torch body, thereby generating a small pocket of plasma gas. This is referred to as
the
pilot arc. The pilot arc has a return electrical path built into the torch head. The
pilot
arc will maintain until it is brought into proximity of the work piece where it
ignites
the main plasma cutting arc. Plasma arcs are extremely hot and are in the range of
15,000 degrees Celsius.
Oxy fuel cuts by burning, or oxidizing, the metal it is severing. It is therefore
limited
to steel and other ferrous metals which support the oxidizing process.
Metals like aluminium and stainless steel form an oxide that inhibits further
oxidization, making conventional oxyfuel cutting impossible. Plasma cutting,
however, does not rely on oxidation to work, and thus it can cut aluminium,
stainless
and any other conductive material. While different gasses can be used for plasma
cutting, most people today use compressed air for the plasma gas. In most shops,
compressed air is readily available, and thus plasma does not require fuel gas and
compressed oxygen for operation.
Plasma cutting is typically easier for the novice to master, and on thinner materials,
plasma cutting is much faster than oxyfuel cutting. However, for heavy sections of
steel (1inch and greater), oxyfuel is still preferred since oxyfuel is typically faster
and, for heavier plate applications, very high capacity power supplies are required
for
plasma cutting applications

ARC STARTING CIRCUIT:

The arc starting circuit is a high frequency generator circuit that produces an AC
voltage of 5,000 to 10,000 volts at approximately 2 megahertz. This voltage is used
to create a high intensity arc inside the torch to ionize the gas, thereby producing
the plasma.
PROCESS:
The basic plasma arc cutting system consists of a power supply, an arc starting circuit
and a torch. These system components provide the electrical energy, ionization
capability and process control that is necessary to produce high quality, highly
productive cuts on a variety of different materials.
The power supply is a constant current DC power source. The open circuit voltage is
typically in the range of 240 to 400 VDC. The output current (amperage) of the
power supply determines the speed and cut thickness capability of the system. The
main function of the power supply is to provide the correct energy to maintain the
plasma arc after ionization.
The arc starting circuit is a high frequency generator circuit that produces an AC
voltage of 5,000 to 10,000 volts at approximately 2 megahertz. This voltage is used to
create a high intensity arc inside the torch to ionize the gas, thereby producing the
plasma.
The Torch serves as the holder for the consumable nozzle and electrode, and provides
cooling (either gas or water) to these parts. The nozzle and electrode constrict and
maintain the plasma.

PLASMA TORCH:
The Plasma cutting process is used with either a handheld torch or a mechanically
mounted torch. There are several types and sizes of each, depending on the thickness
of metal to be cut. Some torches can be dragged along in direct contact with the
work piece, while others require that a standoff be maintained between the tip of the
torch and work piece.
Mechanized torches can be mounted either on a tractor or a on a computer-controlled
cutting machine or robot. Usually a standoff is maintained between the torch tip and
work piece for best-cut quality. The standoff distance must be maintained with fairly
close tolerances to achieve uniform results. Some mechanised torches are equipped
with an automatic standoff controlling device to maintain a fixed distance between
the torch and work piece. In other cases mechanical followers are used to accomplish
this.PAC torches operate at extremely high temperatures, and various parts of the torch
must be considered to be consumable. The tip and electrode are the most vulnerable
to wear during cutting, and cutting performance usually deteriorates as they wear.
The timely replacement of consumable parts is required to achieve good quality cuts.
Modern plasma torches have self-aligning and self-adjusting consumable parts. As
long as they are assembled in accordance with the manufacturer’s instructions, the
torch should require no further adjustent for proper operation.Other torch parts such as
shield cups, insulators, seals etc may also require periodic inspection and replacement if
they are worn or damaged.

Torch Designs:
The Single Flow Torch has only a flow of air for cutting. This is because its use is
limited to lower amperage, thin gauge sheet metal cutting applications. It does not
need a shielding gas flow to cool the torch because of the low amperage output
required for cutting thin gauge sheet metal. The Dual Flow Torch has a flow of gas
or air for the cutting plasma and shielding gas flow for the torch cooling. This is used
for cutting thicker materials, which require higher amperages.
Torch Stand Off:
"Torch stand-off" is the distance the outer face of the torch tip or constricting orifice
nozzle is to the base metal surface. This standoff distance will be determined by the
thickness of material being cut and the amperage required. Low heat build-up while
cutting with less than 40 amperes may allow dragging the torch tip on the material. If
a high build-up of heat is expected, a standoff distance of 1/16" to 1/8" will be
required. This is easily accomplished with a Miller ICE torch with a "Drag Shield".
The "Drag Shield" works with the flow dynamics of the torch to provide better
cooling of the consumable parts for longer parts life. This permits the operator to drag
the torch on the work piece while cutting at full output, which increases operator
comfort and makes template cutting easier.
Torch Stand Off:
Torch Consumables:
The plasma torch is designed to generate and focus the plasma cutting arc. In either
hand held or machine torches, the same parts are used: an electrode to carry the
current form the power source, a swirl ring to spin the compressed air, a tip that
constricts and focuses the cutting arc, and a shield and retaining ring to protect the
torch.

ELECTRODE:
The purpose of the electrode is to provide a path for the electricity
from the power source and generate the cutting arc. The electrode is typically made
of copper with an insert made of hafnium. The Hafnium alloyed electrodes have good
wear life when clean, dry compressed air or nitrogen is used (although, electrode
consumption may be greater with air plasma than with nitrogen).

SWIRL RING:
The swirl ring is designed to spin the cutting gas in a vortex. The swirl
ring is made of a high temperature plastic with angled holes that cause the gas to spin.
Spinning the gas centres the arc on the electrode and helps to control and constrict the
arc as it passes through the tip. The swirl ring on Miller plasma cutting equipment
causes the gas to swirl in a clockwise direction.
TIP:
The purpose of the torch tip is to constrict and focus the plasma arc. Constricting
the arc increases the energy density and velocity. The tips are made of copper, with a
specifically sized hole or orifice in the centre of the tip. Tips are sized according to
the amperage rating of the torch that they are to be used in.
Review of Research Paper:
The present project report on critical study of Optimization of plasma arc cutting process
parameters on SAILMA based on literature review.

1. Investigation Analysis of Plasma arc cutting Parameters on the Unevenness

surface of Hardox-400 material By 1) Subbarao Chamarthi, 2) N.Sinivasa
Reddy, 3) Manoj Kumar Elipey, 4) D.V. Ramana Reddyd. (2013).
Plasma arc cutting (PAC) is a thermal cutting process that makes use of a constricted jet of
hightemperature
plasma gas to melt and separate (cut) metal. In this study 12mm plate thickness
Hardox-400 has been cut by high tolerance voltage, cutting speed, and plasma gas flow rate
included as main parameters in the analysis and their effect on unevenness of cut surface is
evaluated. The design of experiments (DOE) techniques is used in order to outline the main
parameters which define the geometry of the cut profile, as well as its constancy for Hardox-400
material plate. Despite the value selected for these parameters, the analysis shows that Hardox-
400 plates can have different profiles, depending on the specific side considered.
Unevenness can be obtained as a result of an experimental investigation aimed at selecting the
proper values of process parameters of PAC system. Results of this screening step are analyzed
by means of the Analysis of Variance (ANOVA) technique with use of design expert 8.0.7.1
software in order to clearly identify the main parameters, which define the unevenness quality
attribute. The operating conditions have been carefully optimized through parameters adjustment
like cutting speed, plasma gas and arc voltage in order to obtain good surface quality for all the
sides of Hardox-400 plate.
As recorded optimized minimum unevenness for 12 mm Hardox plate is 421 micron at optimum
value of 70L/Hr plasma flow rate, 125 V voltage and 2100 mm/min cutting speed.
30
2. Surface Roughness and MRR Effect on Manual Plasma Arc Cutting
Machining By 1) R. Bhuvenesh, 2) M.H. Norizaman, 3) M.S. Abdul Manan.
(2012).
The roughness of the surface area of the material cut by the plasma arc cutting process and the
rate of the removed material by the manual plasma arc cutting machine was importantly
considered. Plasma arc cutter Selco Genesis 90 was used to cut Standard AISI 1017 Steel of 200
mm x100 mm x 6 mm manually based on the selected parameters setting. The material removal
rate (MRR) was measured by determining the weight of the specimens before and after the
cutting process. The surface roughness (SR) analysis was conducted using Mitutoyo CS-3100 to
determine the average roughness value (Ra).
Taguchi method was utilized to achieve optimum condition for both outputs studied. The
microstructure analysis in the region of the cutting surface is performed using SEM. The results
reveal that the SR values are inversely proportional to the MRR values. The quality of the
surface roughness depends on the dross peak that occurred after the cutting process.
Based on the experiment results several conclusions for manual plasma arc cutting machine can
be highlighted as below:
1) Generally the SR values are inversely proportional to the MRR values.
2) The dimensions of the dross determine the quality of plasma arc cutting in terms of surface
roughness.
3. Experimental Investigation of the Plasma Arc Cutting Process By 1) K.
Salonitis, 2)S. Vatousianos. (2012).
K. Salonitis et al investigated experimentally the plasma arc cutting process in order to assessing
the quality of cut. The quality of cut is assessed by measuring the conicity, edge roughness and
size of heat affected zone (HAZ). The input parameters considered are cutting power, cutting
speed, cutting height and plasma gas pressure. The statistical analysis is performed in order to
determine the contribution of each parameter in the obtained quality of cut. The regression
analysis is done to develop empirical model in order to describe the effect of parameters on the
quality of cutting. Using the design of experiment and analysis of variance it is found that the
surface roughness and conicity are mainly affected by the cutting height, whereas the heat
affected zone (HAZ) is mainly in_uenced by the cutting current.
4. CONSIDERATIONS CONCERNING PLASMA ARC CUTTING
MACHINING By 1) S.M. Ilii, 2) L. Apetrei, 3) I. Carp. (2008).
This paper presents an analysis of the plasma arc cutting (PAC) process, by using the systemic
approach method. After a brief history of PAC is given, the operation principle is described and
the PAC parameters (cutting speed, current intensity, plasma arc voltage, plasmogen gas) are
analyzed. In this paper, the cutting speed parameter is analyzed as an evaluation factor of the
cutting process machinability. The cutting speed represents one of the most important parameters
in the case of plasma cutting process, due to the fact that this parameter has a direct influence on
the productivity of the process and on the quality of the obtain surfaces also.
The plasma arc cutting process was imposed due to the fact that it allows the cutting of highalloy
refractory and stainless steels with maximum productivity, through the automation
capacity, through the low expenses towards traditional techniques, and also due to the quality of
the cut and low thickness of the thermal influence zone (TIZ), within 1.50 mm. By using the
systemic approach method, the authors have identified and analyzed the main input and output
parameters involved in the PAC process, as well as the disturbing factors which can influence the
final result of the PAC process.
5. Optimization of process parameter in plasma arc cutting of EN31 steel
based on MRR and multiple roughness characteristic using grey
relational analysis, 1) Milan kumar, 2) Kaushik kumar, 3) Tapan barman,
4) Prasanta sahoo. (2014).
Milan kumar das and et all were conducted experiment on EN31 steel using process parameters
like gas pressure, arc current and torch height to influence effect on material removal rate and
roughness characteristics. They developed empirical graph of response surface methodology and
finally they worked on chip morphology. They analyzed their experimental reading through
ANOVA and grey relational analysis. They found that highly effective parameter is gas pressure,
whereas arc current and torch height are less effective factors for the response.
6. Optimization of MRR and Surface Roughness in PAC of EN 31 Steel Using
Weighted Principal Component Analysis, 1) Milan Kumar Das, 2) Kaushik
Kumar, 3) Tapan Kr. Barman and 4)Prasanta Sahoo. (2014).
In this paper, an attempt has been made to optimize the process parameters for multi-responses
(material removal rate, MRR and surface roughness) in plasma arc cutting (PAC) of EN 31 steel
using weighted principal component analysis (WPCA). For surface roughness characteristics,
five different surface roughness parameters (center line average roughness: Ra, root mean
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square: Rq, skewness: Rsk, kurtosis: Rku and mean line peak spacing: Rsm) are considered.
Three process parameters viz. gas pressure, arc current and torch height are considered. The
experimental plan is based on Taguchi L27 orthogonal array (OA). To convert the
multiresponses
problem to a single response optimization problem, WPCA is applied to compute a
multi-response performance index (MPI) and then MPI has been optimized using Taguchi
method. The optimum combination of process parameters has been found for maximum MRR
and minimum surface roughness and verified through a confirmation test. Also, ANOVA is
carried out and it is seen that the gas pressure is the most significant factor followed by arc
current.
The machining process parameters (gas pressure, arc current and torch height) are optimized in
order to maximize MRR and minimize the surface roughness in plasma arc cutting of EN 31
steel. Weighted principal component analysis (WPCA) is successfully employed with Taguchi
design of experiments to optimize this multiple response problem. The optimum process
parameter combination is obtained as A3B3C2 (highest level of gas pressure, highest level of arc
current and middle level of torch height). From ANOVA, it is seen that the gas pressure is the
most influencing parameter that significantly affects MRR and surface roughness characteristics
followed by arc current. Among the interactions, interaction between gas pressure (A) and arc
current (B) has the maximum contribution on responses. The confirmation test ensures the
improvement of S/N ratio from the initial to optimal condition and the improvement is about
54%. From this study, it can be concluded that the proposed methodology can be treated as a
very effective and powerful approach to tackle multiple response problems in industrial
experiments.
7. Investigation of the effects of plasma arc parameters on the structure
variation of AISI 304 and St 52 steels, 1) Abdulkadir Gullu , 2 ) Umut
Atici. (2006).
Abdul Kadir Gullu et al investigated the variation in structural specification occurred in the AISI
304 and St 52 carbon steel after cut by the plasma arc. As per the experimental results it is found
that the burning of particulars and distribution amount were increased when the cutting is carried
out using speed and it is observed that the hardness will decreased from the outer surface toward
the core while the hardness at the outer surface affected by the high temperature is increased.
Thus they revealed that the area of 0.399–0.499 mm of stainless steel materials and 0.434–0.542
mm of carbon steel materials were more affected by heat according to cutting speed.
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8. Experimental Investigation of the Plasma Arc Cutting Process, 1) W.J xu,
2) J.C fang, 3) Y.S lu. (2002).
W.J.Xu and et all were conducted experiment on ceramic during plasma arc cutting. They
measured cutting qualities by varing process parameter the flow rate of injected water and the
magnetizing current using nozzles of different diameters. From the experiment they found that
both water constriction and magnetic constriction of plasma arc forms a three dimensional
constriction with improved shape and uniformity of the arc column and hydro magnetic
constriction is capable of improving arc stability.
9. High tolerance plasma arc cutting of commercially pure titanium E, 1) E.
Gariboldi, 2) B. Previtali. (2005).
E. Gariboldi et al [9] investigated the quality of cutting on pure titanium sheet through high
tolerance plasma arc cutting process under various cutting conditions. The 5mm thick sheet of
pure titanium is cut at the various feed rates and with the adaption of oxygen or nitrogen as
cutting and shielding gas. While the oxygen is used as the cutting gas the oxidation reaction will
occur and result in higher feed rates and unevenness and kerf width of better quality were
achieved.
10. Experimental study of the features of the kerf generated by a 200A high
tolerance plasma arc cutting system, 1) R. Bini, 2) B.M. Colosimo, 3) A.E.
Kutlu, 4) M.Monno. (2008).
R.Bini and at all were conducted experiment on 15mm thick mild steel sheets metals using
process parameters like arc voltage and cutting speed, plasma gas flow rate, shield gas flow rate
and shield gas composition are to influence effect on kerf position and shape are evaluated. They
revealed that that cutting speed and arc voltage affect the kerf formation mechanism and their
interaction is also important in defining the inclination of the cut. They also concluded that by
reducing the arc voltage, i.e. the standoff distance, the thermal stress on the torch components,
especially the electrode and the nozzle, increases, thus accelerating their wear. This trade-off can
be taken into account by adding some suitable constraints to the parameters domain and beyond
the arc voltage, the cutting speed showed a noticeable effect. In particular, results obtained in the
last experimental stage allowed one to observe that unevenness can be reduced by reducing the
cutting speed. They were shown that very good quality can be achieved for all the sides by
varying the cutting speed and the arc voltage only.
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11. OPTIMIZING THE QUALITY OF PARTS MANUFACTURED BY THE
AUTOMATED PLASMA CUTTING PROCESS USING RESPONSE
SURFACE METHODOLOGY, 1) B. Asiabanpour, 2) D. T. Vejandla, 3) C.
Novoa, 4) J. Jimenez, 5) R. Fischer. (2009)
Automated plasma cutting is an effective process for building complex two-dimensional metallic
parts in a short period of time. Because the plasma cutting machine has several factors or input
variables to control (e.g., current, cutting speed, torch height) and a variety of part quality
characteristics or response variables to satisfy (e.g., flatness, clean cut, bevel angle), it is very
difficult to find an overall optimum machine setting. In this research, response surface
methodology and desirability functions are used to simultaneously optimize 18 part quality
characteristics. Final results identify an optimal machine configuration that facilitates the
fabrication of parts with close-to-perfect quality for all responses considered.
After analyzing the regression models, this research concludes that the effect of torch height, tool
type, and cut direction plays a critical role in surface quality characteristics. In the future, cost
savings may result of using tool type C, horizontal cut, and a torch height near to 0.3 inches.
High values for current, pressure and slower on curves (80A, 90 psi, and 0.36) are needed to
achieve quality results while an intermediate cut speed of 55 ipm is recommended. The entire
study was conducted for stainless steel sheet metal with 0.25 inch thickness. A similar study can
be done to investigate other popular sheet metal thickness. Also, it would be interesting to
conduct a new similar study incorporating sheet metal thickness as one of the factors.
12. Optimization of plasma arc cutting by applying Taguchi Method, 1)
Kulvinder Rana, 2) Dr. Parbhakar Kaushik, 3) Sumit Chaudhary. (2013).
The aim of the work is the optimization of PAC of mild steel thin plates, both in terms of cut
quality and performances of the consumables, to achieve cut quality standards and productivity
levels usually obtainable through laser cutting processes. PAC of mild steel thin plates of 10 mm
through a KALI-100 Plasma Arc Cutting Machine is operating in the range 25-120 A. The air is
used as plasma gas as well as secondary gas.
In this research, the optimum parameter settings were identified for the plasma cutting process
by using Taguchi L9 orthogonal array, the number of runs required of this design is 9, in this
array we have four variables having three levels so the number of run required if Taguchi
orthogonal array is not used are 3^4 i.e. 81 runs. So by using Taguchi method we have reduced
our number of runs. The main parameters which affect the process are current, air pressure,
stand-off distance, and torch travelling speed. Three levels of these parameters are considered in
increasing order. The entire process in this study was conducted for mild steel sheet with 10 mm
35
thickness. The statistical tool used for determining the optimum process parameters is Taguchi
the software which is used for calculation is Qualitek-4 software which is Automatic Design and
Analysis of Taguchi Experiments. This software provides the information about the selection of
Taguchi design which depends on the number of process variables and the level of their
variation.
The current has maximum effect on the process after that torch travelling speed and stand-off
distance and air pressure have minimum effect on the process. The overall optimum values of
each parameter give the calculation is, the optimum current is 65 A optimum air pressure is 65
psi, optimum torch travelling speed is 3.0 m/min, optimum stand-off distance is 3.0 mm of
having and Heat Affected Zone.
13. On the multi – parameter optimization of CNC plasma-arc cutting process
quality indicators using Taguchi Design of Experiments, 1) J.
KECHAGIAS, 2) P. STAVROPOULOS, 3) S. MAROPOULOS and 4) K.
SALONITIS.
The current study investigates the optimization of cutting parameters during CNC plasma-arc
cutting of St37 mild steel plates utilizing robust design. Process parameters tested include cutting
speed, arc ampere, pierce height, and torch standoff distance utilizing the Taguchi L9 (34) array.
The effect of each parameter has been examined in terms of ANOM (Analysis of Means)
diagrams. Optimum levels for each parameter have been proposed according to performance
measures. ANOVA (Analysis of Variances) has been performed aiming in the importance
identification of each parameter variance onto the performance measure as a percentage value.
Results indicate that the arc ampere has an effect mainly on the bevel angle (58.7%), while the
cutting speed and the torch standoff distance have an influence of 19% and 15.7% respectively.
The pierce height has an influence about 6.6% and thus its variations do not significantly affect
the bevel angle in the experimental region.
14. EXPERIMENTAL RESULTS CONCERNING THE VARIATION OF
SURFACE ROUGHNESS PARAMETER (Ra) AT PLASMA ARC
CUTTING OF A STAINLESS STEEL WORKPIECE, 1) Sanda-Maria Ilii,
2) Margareta CoteaŃă and 4) Adriana Munteanu. (2010).
This paper presents some experimental results concerning the surface roughness variation at
plasma arc cutting, in case of processing a stainless steel work piece. Thus, some experimental
tests were made in an industrial enterprise, on a CNC plasma cutting equipment,
KOMPACT3015-HPR130, in order to analyze the surface roughness parameter obtained during
the cutting process. In order to establish an empirical model of the surface roughness obtained
36
during the plasma cutting process the experimental tests were made using different cutting
conditions. To measure the surface roughness, we used the HANDYSURF E-35A/B apparatus.
In case of processing an austenitic stainless steel work piece AISI 304, by the mathematical
processing of the experimental results by means of the software based on the method of the
smallest squares; we have determined that the material thickness, g [mm], has the most influence
on the Ra roughness surface followed by the cutting speed parameter v [mm/min] and the current
intensity I [A]. The optimal cutting condition in this case is when v = 1000 mm/min, g = 4 mm
and I = 130 A; Ra = 1.77 ìm.
15. Experimental study of the effect of gas Nature on plasma arc cutting of
mild steel, 1) T Kavka, 2) A Maslani, 3) M Hrabovsky, 4) P Krenek, 5) T
Stehrer and 6) H Pauser. (2013).
T Kavka et al investigated the effect of nature of gas on the plasma arc cutting of mild steel. In
this paper the study is been carried out on the in_uence of the nature of gas on the arc behavior
and the cutting performance of mild steel. Usually the plasma arc cutting system is operated on
steam has been modi_ed to usage of different plasma gases. Experimental results are obtained
from the cutting of 16 mm thick mild steel plate at 60 A with steam, nitrogen, air, and oxygen as
the plasma gases. From the experimental results it is concluded that the steam as the plasma gas
will generate more energy than other gases for the same current value and the plasma jet
generated is much narrowed when nitrogen and air is used as plasma gases.
16. QUALITY OF PLASMA CUTTING, 1) Bogdan Nedic, 2) Marko
Jankovic,
3) Miroslav Radovanovic, 4) Gordana Globocki Lakic. (2013).
Bogdan Nedik et al analyzed the quality of cut in plasma arc cutting. In plasma arc cutting
process the quality of cut is defined using standard EN ISO 9013. In this paper the samples of 15
mm thick plates of S235 were used to create 17 cuts. The significant parameters taken in to
consideration are cutting speed and cutting current. The experimental results are found consistent
with theoretical consideration and previous experimental results. It is concluded that the best
quality of cut can be obtained by increasing the cutting speed by 20% than the tablet speed value.
17. Optimization of heat affected zone by partial swarm optimization in air
plasma cutting operation, 1) K Kadirgama, 2) M M Noor, 3) W S W Harun
and 4) K A Aboue-El-Hossein. (2010).
This paper presents development of mathematical model for prediction of heat affected zone
(HAZ) and optimized parameters for air plasma cutting operation on AISI 6061 aluminium alloy.
37
Experimental and predictive values from RSM are found of same trend. Partial swarm
optimization (PSO) was employed to optimize cutting parameters. Deviation of HAZ obtained
by optimized HAZ model is 2.72%. Optimum cutting parameters for minimum HAZ are: output
current, 100 A; stand-off gap, 1 mm and pressure, 620.52 kPa.
18. Investigating the effect of cutting parameters on material cut in CNC
Plasma, 1) Yahya Hisman Selic. (2013).
Yaha hisman selic et al cut the sheet material S235JR using the CNC plasma cutting machine at
different cutting speeds, cutting current, and arc voltage and measured the effect of variation on
temperature distribution, hardness, thickness of heat affected zone and surface roughness of the
material after cut. From the results of the experiments he had concluded that the quality of
plasma CNC machine depend on the cutting current, cutting speed, arc voltage and material
thickness. To get the best surface roughness the cutting current and the cutting voltage kept low
and cutting speed must be high for the thin sheet and while using CNC plasma machine prevent
hardness increase, and have a minimum HAZ. While the thickness of the cutting sheet increase
the cutting current must be increase and cutting voltage is to be decrease. However this leads to
decrease in corresponding cutting speed.
19. Modeling the plasma arc cutting process using ANN, 1) Miroslav
Rodovanovic, 2) Milos Madic. (2011).
Miroslav Radovanovic et al had done a modeling of the plasma arc cutting process using
Artificial Neural Networking (ANN). Aimed to develop the ANN mode to predict the ten point
height of irregularities (Rz) taking input parameters such as cutting speed, cutting current and
plate thickness. After prediction of data the accuracy of ANN has been validated. Using this
model one can select the machining conditions which correspond to the cutting region with
minimal surface roughness.
20. Study on ceramic cutting by plasma arc, 1) W. J. Xu, 2) J. C. fang, 3) Y. S.
Lu. (2002)
W. J. Xu et al [10] used the hydro magnetically confined plasma arc to cut ceramic plates. From
the experiments and analysis the characteristics of hydro magnetic confined plasma was
explored. The effect of secondary confinement on arc properties, on cutting quality and optimal
process parameters were determined. In this paper author conducted various experiments using
water constricted arc, magnetic constricted arc and hydro magnetic constricted arc. After
analyzing the result of experiments it is concluded that by using the hydro magnetic constricted
38
arc a reduced kerf width and improved cut quality on ceramic surface is achieved. Theoretical
and experimental results both have proven the feasibility and validity of the newly advanced
hydro magnetic confined PAC.
21. MATHEMATICAL MODELLING OF PLASMA ARC CUTTING
TECHNOLOGICAL PROCESS, 1) Michal Hatala and 2) Imrich
Orlovský. (2009).
Paper deals with definition and evaluation of process factors and parameters of cut surface while
cutting the material ISO Fe510. Methods of planned experiments are used for these evaluations.
Using factor experiment, importance of four factors was observed (feed rate of plasma torch,
plasma gas pressure, nozzle diameter and distance between nozzle mouth and material), that
influence the parameter of roughness profile Ra and Rz. On the base of results that were
analytically processed by factor analysis it can be said, that impact of process parameters during
the material cutting was different in particular depths. It was found out, that most significant
impact to the machined surface roughness has factors of feed rate of plasma torch and plasma gas
pressure. Among other factors that are less important belongs diameter of nozzle and distance
between nozzle mouth and material. From the experimental results it can be said, that for
achieving higher quality of cut surface it is recommended to use higher pressures of plasma gas
and appropriate feed rate of plasma torch.