Optimization of process parameters in plasma arc cutting of commercial-grade aluminium plate

Abstract

Abstract Plasma arc cutting (PAC) has emerged as a versatile and efficient method for the precision cutting of various materials, including commercial-grade aluminium plates. The optimization of process parameters is crucial for achieving high-quality cuts, minimizing material wastage, and enhancing overall productivity. This study aims to systematically investigate and optimize the key process parameters in PAC of commercial-grade aluminium plates. The experimental design involves the manipulation of parameters such as arc current, gas pressure, and workpiece thickness. A Design of Experiments approach, specifically Taguchi’s orthogonal array, is employed to efficiently explore the parameter space and identify the optimal combination of settings. The response variables considered for optimization include minimum surface roughness, minimum burr height, and maximum material removal rate (MRR). Analysis of variance is performed to get the percentage influence of each process parameter on the performance characteristic. The results obtained from the optimization process are expected to provide valuable insights into enhancing the efficiency and precision of PAC for commercial-grade aluminium plates. Arc current is found to be the most significant parameter in altering the surface roughness. The thickness of the material is the most significant parameter in altering burr height. None of the parameters is found to be significant in altering the MRR from Analysis of Variance analysis. From signal-to-noise ratio analysis and average performance graph, the optimum combination of processes in altering the bur height and MRR are found as arc current at 50 amp, the gas pressure at 5.4 bar, and the thickness of the workpiece at 6 mm.