Lab Session: 6

6.1 Title
Video graphic demonstration and discussion on working and basic principle of plasma arc
cutting machine

6.2 Objectives
The main objectives of this is
1. To know about the Plasma Arc Cutting Process
2. To understand the process on the basis of Research Paper

6.3 Introduction
Plasma arc cutting, also referred to as plasma fusion cutting or plasma cutting, is a
fabrication process which employs superheated, ionized gas funneled through a plasma torch to
heat, melt and, ultimately, cut electrically conductive material into custom shapes and designs.

The plasma arc cutting process is a thermal-based fabrication process which utilizes a
constricted, transferred plasma arc to cut through a wide range of metals, including structural
steel, alloy steel, aluminum, and copper. While there are several variations available, the basic
principles of the process and the necessary components remain the same throughout all of them.
The primary plasma arc cutting process includes the following phases:

1. Pilot arc initiation

2. Main arc generation
3. Localized heating and melting
4. Material ejection
5. Arc movement

[4]
Figure 1 Plasma Arc Cutting
The plasma cutting process is often presented as an alternative solution to laser cutting,
waterjet cutting, and oxy-fuel cutting, and offers certain advantages over these options,
including faster cutting times and lower initial investment and operational costs. While
plasma cutting demonstrates some advantages over these other cutting processes, its use in
some manufacturing applications can be problematic, such as cutting non-conductive
material. [4]

6.4 Problem Statement

Manual plasma cutters are generally used by workshops for thin metal processing, factory
maintenance, agricultural maintenance, welding repair centres, metal service centres (scrap,
welding and dismantling), construction work (e.g. buildings and bridges), commercial
shipbuilding, trailer production, car repair and works of art (manufacturing and welding).
Typical materials that can be cut with a plasma torch are steel, stainless steel, aluminium, brass,
copper and other conductive metals. Plasma cutting is widely used in manufacturing, automotive
repair and restoration, industrial construction, salvage and scrapping. [5]

[2]
Figure 2 Application of Plasma Arc Cutting

6.5 Working Principle

The basic plasma cutting process involves creating an electrical channel of

superheated, electrically ionized gas i.e. plasma from the plasma cutter itself, through the work
piece to be cut, thus forming a completed electric circuit back to the plasma cutter through
a grounding clamp. This is accomplished by a compressed gas (oxygen, air, inert and others
depending on material being cut) which is blown through a focused nozzle at high speed toward
the work piece. An electrical arc is then formed within the gas, between an electrode near or

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integrated into the gas nozzle and the work piece itself. The electrical arc ionizes some of the
gas, thereby creating an electrically conductive channel of plasma. As electricity from the cutter
torch travels down this plasma it delivers sufficient heat to melt through the work piece. At the
same time, much of the high velocity plasma and compressed gas blow the hot molten metal
away, thereby separating, i.e. cutting through, the work piece.
Plasma cutting is an effective way of cutting thin and thick materials alike. Hand-held torches
can usually cut up to 38 mm (1.5 in) thick steel plate, and stronger computer-controlled torches
can cut steel up to 150 mm (6 in) thick.[1] Since plasma cutters produce a very hot and very
localized "cone" to cut with, they are extremely useful for cutting sheet metal in curved or angled
shapes.

The arcs are generated in a three step process. A high voltage spark briefly ionizes the air within the torch
head. This makes the air conductive and allows the "pilot arc" to form. The pilot arc forms within the
torch head, with current flowing from the electrode to the nozzle inside the torch head. The pilot arc burns
up the nozzle, a consumable part, while in this phase. The air then blows the plasma out the nozzle
towards the work, providing a current path from the electrode to the work. When the control system
senses current flowing from the electrode to the work, it cuts the electrical connection to the nozzle.
Current then flows from the electrode to the work, and the arc forms outside the nozzle. Cutting can then
proceed, without burning up the nozzle. Nozzle life is limited by the number of arc starts, not cutting
[5]
time.

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6.6 Apparatus Diagram

Figure 3 Plasma Arc Machine [3]

6.7 Material Considerations

As the plasma arc cutting process employs transferred plasma arcs, its use is limited to cutting
only materials that are electrically conductive. However, it is suitable for a wide range of metals,
including:

 Structural steel
 Non-alloy, low-ally, and high-alloy steel
 Aluminum
 Clad metal plates

Plasma arc cutting can also be used on materials such as copper, brass, titanium, and cast iron,
although some of their melting temperatures may prove to be problematic in achieving a high-
quality edge cut. Depending on the specifications of the plasma arc cutting machine and the
workpiece material, the process is capable of cutting through material thicknesses ranging
between 0.5 mm to 180 mm.

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6.8 Construction of Plasma Arc Cutting Machine

The plasma arc cutting torch carries a tungsten electrode fitted in the chamber. This tungsten
electrode is connected to the negative terminal of the DC power supply. For plasma arc
machining, a plasma gun is required. This plasma gun has a chamber. This plasma gun has a
tungsten electrode fitted inside the chamber.
This tungsten electrode is connected to the negative terminal of DC Power Supply and acts as a
cathode. At the bottom of the chamber, there is a copper nozzle that is connected to a positive
terminal of the DC Power Supply and acts as an anode. The rest of the chamber is made of
insulating material and acts as an insulator. [6]
Gas enters the chamber through a small passage present at the right side of the chamber.
The cathode and the anode remain cool despite the hot gases passing through them as they are
water cooled. Water circulation is present around the torch.
Power Source: The power source provides the energy to initiate the pilot arc and maintain the
main arc throughout the plasma arc cutting process. They typically have high, non-load voltages
(i.e., open-circuit voltages) ranging from 240VDC to 400VDC to produce the pilot arc, but only
require 50VDC to 60VDC to sustain the main arc once it is produced.
Arc Starting Console (ACS): The ACS produces the initial spark which initiates the pilot arc
circuit.
Gases and Media Employed: Plasma gases are categorized into ignition gases (ignites the
plasma arc), cutting gases (used with the plasma arc during the cutting process), and secondary
gases (constricts and cools the plasma arc). Gases employed can be inert, reactive, or a mixture
of the two previous types. Water is also employed as a secondary medium during the cutting
process.
Torch Assembly: The torch assembly and parts includes the electrode and the nozzle, is
connected to the power supply, and utilizes the plasma and cutting gases to initiate and perform
the plasma cutting operation.
Cooling System: The cooling system cools the torch assembly components and workpiece,
extending the lifespan of the consumables. The system can be either water or gas-cooled.
Workpiece: The workpiece is the material being cut. The material must be electrically
conductive to be plasma cut as the workpiece serves as a component of the main arc circuit.
Other options for plasma arc cutting setups include cutting benches, air pollution control
equipment, and overhead track systems. The cutting bench serves as a work surface for cutting
the workpiece, and the control equipment as a means of removing emissions formed during the
cutting process. For automated cutting machines, the torch is suspended overhead on a track
[7]
system to allow for movement across the workpiece’s surface.

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 [7]
Figure 4 Consumable plasma torch nozzles

6.9 Working Procedure

1. At first, when a D.C power is supplied to the circuit, a strong arc is produced between the
cathode (electrode) and the anode (nozzle).
2. After that, gas is supplied to the chamber. This gas can be hydrogen, nitrogen, argon or
mixture of these gases chosen according to the metal to be worked.
3. The gas used in the process is heated using the arc produced between the cathode and the
anode. This gas is heated to very high temperatures from 11000 °C to 28000 °C.
4. As the arc comes into contact with the gas, there is a collision between the electron of the
arc and the molecules of the gas and the molecules of the gas will dissociate into separate
atoms.
5. Due to the high temperature generated from the arc, electrons from some atoms will be
displaced and atoms are ionized (electrically charged) and the gas turns into plasma. As
the gas is ionized, a large amount of thermal energy is liberated.
6. After the gas is ionized, this high temperature ionized gas is directed towards the
workpiece with high velocity.
7. The electric arc has some other benefits like it increases the temperature of ionized gas,
makes the beam almost parallel, and increases the velocity of the gas.
8. As the plasma jet reaches the workpiece, the plasma melts the workpiece and the high-
velocity gas blows away the molten metal.
9. In this way, plasm arc machining is used to remove material from the workpiece. [8]

6.10 Variants of the Plasma Arc Cutting Process

The basic principles behind the plasma arc cutting process remain the same across the different
variations available. However, each process variation provides particular advantages in regards

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to manufacturing applications based on the material being cut and its properties, the power
output, and specific requirements of the application. The variations are typically differentiated
based on their cooling system, the type of plasma gas, the design of the electrode, and the type of
plasma employed. [9]

Some of the plasma arc cutting options available include:

 Standard (or conventional) plasma arc cutting

 Plasma arc cutting utilizing a secondary medium
 Water injection plasma arc cutting

Other variations of plasma arc cutting include:

 Plasma arc cutting with increased constriction

 Underwater plasma arc cutting
 Plasma gouging
 Plasma marking

6.11 Applications of Plasma Arc Cutting Machining

 It is used in mill applications.

 It is also used in the nuclear submarine pipe system.
 Used in welding rocket motor case.
 Used in welding of stainless steel tubes.
 It is used for profile cutting.
Manual plasma cutters are generally used by workshops for thin metal processing, factory
maintenance, agricultural maintenance, welding repair centres, metal service centres (scrap,
welding and dismantling), construction work (e.g. buildings and bridges), commercial
shipbuilding, trailer production, car repair and works of art (manufacturing and welding). [9]

6.12 Advantages of Plasma Arc Cutting Machining

Advantages:

 Operation of one or more burners depending on the series

 Cutting of all electrically conductive materials
 Cutting of high-alloy steel and aluminium materials in medium and large thicknesses
 Excellent performance in small and medium mild steel thicknesses
 Cutting of high-strength structural steel with lower heat input
 High cutting speeds (up to 10 times higher than with oxyfuel)
 Any processing of high-quality blanks for medium and thick sheet metals

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  Plasma cutting guarantees automation
 Plasma cutting under water allows very low heat exposure and low noise level at the
workplace. [9]

6.13 Limitations of Plasma Arc Cutting Machining

Disadvantages

 Restriction of use of up to 160 mm (180 mm) for dry cutting and 120 mm for underwater
cutting
 A slightly wider kerf
 Relatively high power consumption
 Lasers offer an even higher cutting quality
 More expensive than oxyacetylene cutting systems
 Noise development possible with dry cutting
A major limitation in implementing a plasma welding process is the relatively high start-up
costs. Plasma welding equipment tends to be expensive. Because it is a more specialized welding
[9]
process, the training and expertise required is also more intense.

6.14 Safety Precautions for Plasma Arc Cutting

1. Fire Prevention
2. Explosion Prevention
1. Electric Shock Can Kill
2. Toxic Fumes Produced by Plasma Cutting
3. Plasma Arc Can Cause Injury and Burns
4. Arc Rays Can Burn the Eyes and Skin
5. Grounding Safety
6. Compressed Gas Equipment Safety
7. Noise Can Damage Hearing

6.15 Conclusions

Outlined above are the basics of the plasma arc cutting machine and process, various plasma
cutting variations, and some of the considerations that may be taken into account by
manufacturers and machine shops when deciding whether plasma cutting is the most optimal
solution for their particular cutting application.

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6.16 Research Article for Plasma Arc Cutting Process

6.16.1 Title

Optimization of plasma arc cutting by applying Taguchi Method

6.16.2 Published by

1. Kulvinder Rana
M.Tech. Scholar, U.I.E.T., M.D.U., Rohtak, Haryana
2. Dr. Parbhakar Kaushik
Assistant Professor, ME Dept., U.I.E.T., M.D.U., Rohtak, Haryana
3. Sumit Chaudhary
Assistant Professor, ME Dept., MAIT, New Delhi, India

6.16.3 Purpose of Research Paper

This research is carried out on KALI-100 Model of Plasma Arc Cutter. We can have four
variables in this models which are current, torch travelling speed, Torch Stand-off distance,
supply air pressure. The output parameter is Heat Affected Zone which is to be minimized to
have optimized settings of process parameters. The statistical tool used in the research is Taguchi
Method. Taguchi L9 orthogonal array is used for the calculation of optimum process parameters.
The percentage effect of each process variable is also studied.

6.16.4 Index Terms

Taguchi, Plasma arc cutting, ANOVA, HAZAV.

6.16.5 Introduction
Basically there are three states of matter i.e. solid, liquid and gas. The basic difference between
them is of energy. Energy of solid is minimum. If we add energy to solid, it is converted into
liquid. If we add extra energy to liquid it is converted into gas, when we add extra energy to gas,
it becomes plasma. Plasma is highly ionized and electrically conductive. It is much useful to
increase temperature as well as to perform cutting. Plasma cutting technology is one in which
argon, nitrogen and compressed air are used to generate a plasma jet and then nonferrous metal,
stainless steel and black metal are cut by the high temperature of the highly-compressed plasma
arc and the mechanical erosion of the fast plasma jet.

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 Figure 5 Schematic Diagram of PACM
The Taguchi method, a systematic application in design and analysis of experiments, is used for
Designing and improving product quality. It has become a powerful tool for improving
productivity during research and development so that high quality products can be produced and
cost is reduced. However, the original Taguchi method was designed to optimize a single
performance characteristic. 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. Minitab
provides both static and dynamic response experiments.

6.16.6 Input and output parameters

Input Parameter
1. Flame cutting thickness: 6-150mm.
2. Cutting speed: 50-4000mm/min.
3. Work voltage: 220/380V +-10% 50Hz
4. Cutting air pressure: 1.2MPa
5. Cutting oxygen pressure :< =1.0MPa.
6. Plasma Gas pressure :< =0.25MPa.
7. Work temperature :< =50 C.

Output Parameters
1. Heat affected zone.
6.16.7 Calculations

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

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design which depends on the number of process variables and the level of their variation. The
design of experiment is complete in this stage. The combination of the various process variables
is given after the selection of Taguchi orthogonal Array.
In our research the number of variables is four and their level is three so we have the Taguchi L9
orthogonal Array for the study. The levels of the various process variables are given as input to
the software. The output parameter which is used for controlling the process is the kerf and Heat
Affected Zone. Both are undesirable so we have to minimize both kerf and Heat Affected Zone.
So we take the condition of smaller is better for our calculations. The calculation will be on the
basis of average of values.

6.16.8 Results

Analysis using Average of Results

We will take nine experiments with three runs and we take average of results. The average value
of experimental run of heat affected zone is explained in table below.

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 Figure 6 Results of our Observations

6.16.9 Observations

In this research the calculation is done on the basis of average of values. The Main Effect of all
the parameters is calculated. The Multiple Graph is plotted which shows the effect of variation of
the parameters on a single plot. Moreover, it gives the idea about the extent upto which a factor
effects the process graphically. ANOVA gives the percentage effect of all the factors i.e. it tells
about the percentage or parameters according to their effect on the process. The finally the
optimum conditions and performance is given which tell about the optimum value of process
variables which gives the best performance according to the desired constraints i.e. smaller is
better in our case.
Observation Heat Affected Zone Response using Average of Results
The effect of current is maximum on the process which is more the 65% after that speed have a
effect of about 34% and stand-off distance and air pressure have minimum effect on the process.
Their combined effect is less the 1% on the process. The optimum values of each parameter is
given by table 7.8, the optimum current is 65 A optimum air pressure is 60 psi, optimum torch
travelling speed is 3.0 m/min, optimum stand-off distance is 3.0 mm of having minimum HAZ
which is calculated by average of results.

6.13.10 Conclusions
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 effect 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
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

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6.17 References

1. Ramakrishnan S, Shrinet V, Polivka F, Kearney TN, Koltun P. 2000, “Influence of Gas

Composition on Plasma Arc Cutting of Mild Steel”, Journal. of Physics, 33, 2000 (18).
2. Joseph C. Chen, Ye Li, Ronald A. Cox, “Taguchi-based Six Sigma Approach to Optimize
Plasma Cutting Process: An Industrial Case Study”, International Journal of Advanced
Manufacturing Technology, 41, 2009, pp. 760-769.
3. Y. F. Hsiao, Y. S. Tarng, and W. J. Huang, “The optimal parameters process of plasma
arc welding (PAW) by the Taguchi method with Grey relational analysis is studied”, 23,
2008, pp. 51-58.
4. Mahapatra, S.S., Amar Patnaik, "Optimization of wire electrical discharge machining
(WEDM) process parameters using Taguchi method", Vol. 34, (2007) pp. 911-925.
5. John Kechagias, Michael Billis, Stergios Maropoulos, “An optimization of the cutting
parameters during CNC plasma-arc cutting of St37 mild steel plates is attempted using
robust design”, Volume 1 - Issue 4 – 2010, pp.562-571.
6. Ryoichi F, “Elimination of various quality nonconformities, reduction in failure and cost
by half by using Taguchi design method”, Vol. 36 No. 3 October 2003 pp 168-173.
7.  "Making plasma cutting easier". www.thefabricator.com.
8. ^ "Eye and face protection. - 1910.133". www.osha.gov. Retrieved 2015-09-27.
9. ^ "How To Use A Plasma Cutter - A Comprehensive Beginners Guide".
10. ^ Sacks, Raymond; Bohnart, E. (2005). "17". Welding Principles and Practices (Third
ed.). New York: McGraw_Hill. p. 597. ISBN 978-0-07-825060-6.

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