OPTIMIZATION OF PLASMA ARC

CUTTING PROCESS PARAMETERS FOR

SAILMA MATERIAL

KETUL N. PRAJAPATI
ROLL NO: 13014041011

Department of Mechanical Engineering

U. V. Patel College of Engineering
Ganpat University
Kherva, Mehsana-384012 (North Gujarat)
 OPTIMIZATION OF PLASMA ARC
CUTTING PROCESS PARAMETERS FOR
SAILMA MATERIAL
A DISSERTATION SUBMITTED TO
U. V. PATEL COLLEGE OF ENGINEERING
GANPAT UNIVERSITY
IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE
DEGREE OF
MASTER OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
WITH SPECIALIZATION IN
CAD / CAM

SUBMITTED BY

KETUL N. PRAJAPATI
(ROLL NO. 13014041011)

UNDER THE GUIDANCE OF

PROF. H. R. SATHAVARA
APRIL-2015

Department of Mechanical Engineering

U. V. Patel College of Engineering
Ganpat University
Kherva, Mehsana-384012 (North Gujarat)
 Department of Mechanical Engineering
U. V. Patel College of Engineering
Ganpat University
Kherva, Mehsana-384012 (North Gujarat)

Certificate
This is to certify that the Work Presented in the Dissertation entitled
“OPTIMIZATION OF PLASMA ARC CUTTING PROCESS
PARAMETERS FOR SAILMA MATERIAL” being submitted by
KETUL N. PRAJAPATI (13014041011) in regards to the partial
fulfillment for the requirement for the award of the degree of Master of
Technology in Mechanical Engineering with specialization in CAD /
CAM during the academic session 2014-2015 is a record of bona fide work
carried out by him at the Department of Mechanical Engineering, U. V.
Patel College of Engineering, Ganpat University under my guidance and
supervision. The work done here is a reflection of originality and
transparency. The work incorporated in this thesis has not been, to the best of
my knowledge, submitted to any other University or Institute for the award
of any degree or diploma.

Prof. H. R. Sathavara Dr. V. B. Patel

Guide, Assistant Professor, Head of Mechanical
Mechanical Engg. Department, Engineering Department,
U.V.P.C.E., Ganpat University, U.V.P.C.E., Ganpat
Kherva, Mehsana. University, Kherva, Mehsana.

Dr. P. H. Shah
Principal,
U.V.P.C.E., Ganpat University,
Kherva, Mehsana.
 Department of Mechanical Engineering
U. V. Patel College of Engineering
Ganpat University
Kherva, Mehsana-384012 (North Gujarat)

Certificate of Examination

This is to certify that we have examined the thesis entitled

“OPTIMIZATION OF PLASMA ARC CUTTING PROCESS
PAERAMETERS FOR SAILMA MATERIAL” submitted by KETUL N.
PRAJAPATI (13014041011), a postgraduate student of Mechanical
Engineering with specialization in CAD / CAM. We hereby accord our
approval of it as a study carried out and presented in manner required for its
acceptance in partial fulfillment for the Post Graduate Degree for which
it has been submitted. This approval does not necessarily endorse or accept
every statement made, opinion expressed or conclusion drawn as recorded in
this thesis. It only signifies the acceptance of the thesis for the purpose for
which it is submitted.

External Examiner Internal Examiner

 ACKNOWLEDGEMENT
First and foremost, I wish to express my sincere appreciation to my project guide Prof. H.
R. SATHAVARA and Co. guide Prof. D. K. Soni, Department of Mechanical and
Mechatronics engineering, U.V.P.C.E, Ganpat University, a decent and disciplined
personality, keep interest, giving immense encouragement, inspiring guidance,
constructive criticism and fruitful suggestions, throughout the course of my studies and
completion of this manuscript.

I would also like to acknowledge with much appreciation the crucial role of Mr. T. M.
Patel and Mr. Yash Raj, Gujarat Apollo Equipments Ltd., Dholasan for providing the
facilities to perform the experiment work during my study.

I would also like to thank Dr. V. B. Patel, Head of Mechanical Engineering Department,
Dr. B. P. Patel, Mechanical and Mechatronics Engineering Department and Prof C. P.
Patel, PG Coordinator, Mechanical and Mechatronics Engineering Department that have
always been prepared to offer me help at any time, in spite of having busy schedule. I
would also like to thank Dr. P. H. Shah, Principal, for whole hearted support.

I am thankful to all teaching and non-teaching faculty members of Mechanical and

Mechatronics engineering department, and all staff members of U. V. Patel College of
Engineering, Kherva for providing help me directly or indirectly in bringing of this piece
of work successful completion.

It is beyond my limitations to acknowledge in words the unending help and inspiration

received from my dear colleagues with whom I went hand in hand during my study and
research work. I was fortunate enough to share joyful times with achates to Ujjval, Ravi,
Nitesh, Dinesh, Nisarg, Nikhil, Rahul, Mehul, Jay, Vipin, Nilesh Sunil, Ravi, and Biraj.

My words seems extinguished while conveying the depth of my feelings of respect and
gratitude to “My Parents” and my Family who constantly showered their love and
blessings which acted as a catalyst without which this achievement would have remained
a dream. I would like to dedicate this dissertation work to “My Parents”.

I
Indeed the words at my command are not adequately enough to convey the depth of my
feeling for Goddess who bestowed their blessings upon me throughout my life.

Date: / /2015 PRAJAPATI KETUL N.

13014041011

II
 ABSTRACT
In last forty years there is tremendous research in machining and development in
technology. With increase in competition in market and to attain high accuracy now a days
the nonconventional machining are become lifeline of any industry. One of the most
important non-conventional machining methods is Plasma Arc Machining. Its high
accuracy, finishing, ability of machining any hard materials and to produce intricate shape
increases its demand in market.

This dissertation work focuses on finding out the optimum parameters in plasma arc
cutting for machining of SAILMA. With the use of plasma arc cutting machine the cutting
is possible by using different process parameters as cutting speed, arc current, gas
pressure, arc gap, kerf, etc, and gets the changes in response variables like surface
roughness and material removal rate.

To optimization of all these parameters with multi responses characteristics based on the
Grey Relational Analysis. By analyzing grey relational grade, it is observed that which
parameter has more effect on responses of process parameters to the response variables.
Our team has used three process parameters (cutting speed, arc current, gas pressure) and
two response variables (surface roughness, material removal rate).

The experimental results are corresponding to the effect of different cutting speed (2850,
3150, 3450, 3750, 4050 mm/min), different arc current (80, 130 amp) and different gas
pressure (80, 100, 120 kgf/cm2), on the SAILMA plate of 100 mm × 100 mm × 6 mm.

From the experimental results for ANOVA analysis it conclude that for surface roughness
percentage contribution of gas pressure is more in three response variables compare to
other two process parameters and for material removal rate percentage contribution of arc
current is more in three response variables compare to other two process parameters. Also
from grey relational analysis it concludes that 10th experiment give multi-performance
characteristics of the plasma arc cutting process among the 30 experiments. From grey
relational analysis it will also conclude that the optimum parameter level for cutting speed,

III
arc current and gas pressure are level 2 (3150 mm/min), level 2 (130 amp) and level 1 (80
kgf/cm2) respectively.

The results shows its better surface roughness and material removal rate prediction
capabilities and applicability to such industrial plasma arc cutting leading to effective
selection of machining parameter for better qualitative cutting.

IV
 TABLE OF CONTENT
TITLE PAGE NO.
Acknowledgement I
Abstract III
Table of Content V
List of Figures X
List of Tables XII
List of Abbreviation XIV

Chapter 1 Introduction 1-28

1.1 Overview 1
1.2 What is Plasma? 2
1.3 Ionisation 2
1.4 History and Development of Plasma Arc Process 3
1.4.1 Transferred and Non-Transferred Modes 4
1.4.2 Altering the Characteristics of the Plasma Jet 5
1.4.3 Conventional Plasma Arc Cutting (1957) 5
1.4.4 Dual Flow Plasma Arc (1962) 6
1.4.5 Air Plasma Cutting (Since 1963) 7
1.4.6 Water Shield Plasma Cutting (1965) 7
1.4.7 Water Injection Cutting (1968) 8
1.4.8 Water Muffler and Water Table (1972) 9
1.4.9 Underwater Cutting (1977) 10
1.4.10 Underwater Muffler 10
1.4.11 Low-Amp Air Plasma Cutting (1980) 11
1.4.12 Oxygen Plasma Cutting (1983) 11
1.4.13 Oxygen Injection Plasma Cutting (1985) 12

V
 1.4.14 Deep Water Plasma Cutting 12

1.4.15 High Density Plasma Cutting (1990) 13

1.4.16 Laser Lasting Consumable Parts (1990) 13

1.5 Introduction of CNC Plasma Cutting Machine 13

1.6 Principle of Plasma Cutting Machine 14
1.7 Process Description 15
1.8 Shielding and Cutting Gases for Plasma Cutting 19
1.9 Plasma Gas Selection 19
1.9.1 Air Plasma 19
1.9.2 Nitrogen Plasma 20
1.9.3 Argon/Hydrogen Plasma 20
1.9.4 Oxygen Plasma 20
1.10 Secondary Gas Selection for Plasma Cutting 20
1.10.1 Air Secondary 20
1.10.2 CO2 Secondary 20
1.11 System 21
1.12 Plasma torch 22
1.13 Torch consumables 22
1.13.1 Electrode 23
1.13.2 Swirl ring 24
1.13.3 Nozzle 24
1.14 Plasma torch consumables specification for Different material 25
1.15 Introduction to problem 26
1.16 Problem statement 26
1.17 Objectives 27
1.18 Scope 27
1.19 Significance of findings 28

VI
1.20 Summary 28

Chapter 2 Literature Review 29- 38

2.1 Introduction 29
2.2 Review of Research Paper 29
2.3 Identified Gaps in the Literature 38
2.4 Summary 38

Chapter 3 Design of Experiment 39-46

3.1 Introduction of Parameter 39
3.2 Design Factors 39
3.2.1 Process parameters 39
3.2.1.1 Cutting Speed 39
3.2.1.2 Arc Current 40
3.2.1.3 Gas Pressure 40
3.2.2 Response variables 40
3.2.2.1 Surface roughness 40
3.2.2.2 Material removal rate 41
3.3 Design of Experiment 41
3.3.1 Introduction 41
3.3.2 Phases of design of experiment 42
3.3.3 Methods of DOE 43
3.4 Full Factorial Method 44
3.4.1 Steps in full factorial design 44
3.4.2 Selection of process parameters 44
3.4.3 Experimental design 45
3.5 Summary 46

VII
Chapter 4 Experimental Setup and Measurement 47-54
4.1 Machine description used in industry 47
4.2 Material Selection 48
4.3 Surface Roughness Measurement 49
4.3.1 Technical specification of surface roughness tester 50
4.4 Material Removal Rate Measurement 51
4.5 Experimental Result 53
4.6 Summary 54

Chapter 5 Analysis of Variance 55-65

5.1 Analysis of Variance 55
5.1.1 Introduction 55
5.1.2 Analysis of variance terms and notations 55
5.2 Analysis of Variance for Surface Roughness 58
5.3 Analysis of Variance for Material Removal Rate 61
5.4 Result Discussion 65
5.5 Summary 65

Chapter 6 Multi Response Optimization 66-77

6.1 Grey Relational Analysis for Multi Objective Optimization 66
6.1.1 Data pre-processing 66
6.1.2 Grey relational coefficient and Grey relational grade 67
6.2 Process Steps for Multi Response Optimization 68
6.3 Normalization of Experimental Results 68
6.4 Calculation of Deviation Sequence 70
6.5 Calculation of Grey Relational Coefficient and Grey Relational Grade 71
6.6 Analysis and Discussion of Experimental Results 74

VIII
 6.6.1 Graph for grey relational grades 74
6.6.2 Main effect plot for grey relational grade 75
6.7 Confirmation Test 77
6.8 Summary 77

Chapter 7 Result and Discussion 78-84

7.1 Main Effect Plot for Process Parameters v/s Response Variables 78
7.2 Interaction Plots for Process Parameters v/s Response Variables 81
7.2.1 Interaction effect for surface roughness 81
7.2.2 Interaction effect for material removal rate 82
7.3 Summary 83

Chapter 8 Conclusion 84-85

Future Scope 86

References 87-89

Appendix 90
Appendix 1 90

IX
 LIST OF FIGURES
FIGURE NO. FIGURE TITLE PAGE NO.
Fig 1.1 Generation of plasma 2
Fig 1.2 Temperature profiles for TIG arc and plasma jet (right) 4
Fig 1.3 TIG welding arc 4
Fig 1.4 Transferred and non-transferred modes 5
Fig 1.5 Dual flow plasma cutting 7
Fig 1.6 Water injection plasma cutting 8
Fig 1.7 Oxygen injection plasma cutting 12
Fig 1.8 CNC Plasma cutting machine 14
(At. GUJARAT APOLLO EQUIPMENTS LTD.,
DHOLASAN)

Fig 1.9 Principle of plasma cutting machine 15

Fig 1.10 While the metal to be cut (work piece) is connected directly to 17
positive. Gas flows through the nozzle and exits out the orifice.
There is no arc at this time as there is no current path for the
DC voltage

Fig 1.11 It is done in such a way that the gas must pass through this 17
arc before exiting the nozzle

Fig 1.12 Current flow to the work piece is sensed electronically now 18
the high frequency is disabled and the pilot arc relay is opened.
Gas ionization is maintained with energy from the main DC arc

Fig 1.13 At this time, torch motion is initiated and the cutting process begins 18

Fig 1.14 Plasma Arc Cutter System 21

Fig 1.15 Assembly of torch consumables 23

Fig 1.16 Electrode 23

Fig 1.17 Swirl ring 24

Fig 1.18 Nozzle 24

X
Fig 4.1 Tool of plasma cutting machine 47
(At. GUJARAT APOLLO EQUIPMENTS LTD., DHOLASAN)

Fig 4.2 Messer plasma cutting machine use in company 48

(At. GUJARAT APOLLO EQUIPMENTS LTD., DHOLASAN)

Fig 4.3 Mitutoyo surface roughness tester SJ-201 51

Fig 5.1 ANOVA of SR in Minitab software 61
Fig 5.2 ANOVA of MRR in Minitab software 65
Fig 6.1 Graph for grey relational grades 74
Fig 6.2 Graph of grey relational grade v/s cutting speed 75
Fig 6.3 Graph of grey relational grade v/s arc current 76
Fig 6.4 Graph of grey relational grade v/s gas pressure 76
Fig 7.1 Graph of main effect plot for surface roughness 78
Fig 7.2 Graph of main effect plot for material removal rate 79
Fig 7.3 Graph of main effect plot for grey relational grade 80
Fig 7.4 Interaction effect of cutting speed and arc current on surface roughness 81
Fig 7.5 Interaction effect of cutting speed and gas pressure on surface roughness 81
Fig 7.6 Interaction effect of arc current and gas pressure on surface roughness 82
Fig 7.7 Interaction effect of cutting speed and arc current on material removal 82
rate
Fig 7.8 Interaction effect of cutting speed and gas pressure on material removal 83
rate
Fig 7.9 Interaction effect of arc current and gas pressure on material removal 83
rate

XI
 LIST OF TABLES
TABLE NO. TABLE TITLE PAGE NO.
Table 1.1 Summary Table for Gas Selection 21

Table1.2 Plasma torch consumables specification for mild steel 25

Table1.3 Plasma torch consumables specification for stainless steel 25

Table1.4 Plasma torch consumables specification for aluminum 25

Table 3.1 Process parameters and response variables 39

Table 3.2 Fixed variables 39

Table 3.3 Process parameters with levels value 45

Table 3.4 Fixed variables value 45

Table 3.5 Process parameters levels and range 45

Table 4.1 Chemical composition of SAILMA 49

Table 4.2 Properties of SAILMA 49

Table 4.3 Technical specification of Mitutoyo surface roughness tester SJ-201 50

Table 4.4 MRR calculation sheet 51

Table 4.5 Result of surface roughness and material removal rate obtain from 53
experimental work

Table 5.1 Process parameters with level range 56

Table 5.2 Range of process parameters and response variables 56

Table 5.3 Summary of ANOVA calculation for SR 60

Table 5.4 Summary of ANOVA calculation for MRR 64

Table 6.1 Quality characteristics of the machining performance 66

Table 6.2 Data Pre-Normalization 68

XII
Table 6.3 Deviation sequences 70

Table 6.4 Calculation of grey relational coefficient and grey relational grade 72

Table 6.5 Response table for grey relational grade 74

XIII
 LIST OF ABBREVIATION
Symbol Description
PAC Plasma Arc Cutting

CNC Computer Numerical Controlled

ANN Artificial Neural Network

WRW Work piece Removal Weight

WRV Work piece Removal Volume

AISI American iron and steel institute

SS Stainless steel

MS Mild steel

SR Surface roughness

MRR Material removal rate

GRA Grey relational analysis

GRC Grey relational coefficient

GRG Grey relational grade

XIV
 CHAPTER 1
INTRODUCTION

1.1 OVERVIEW

The topic for the thesis writing is the Optimization of Process Parameters of Plasma Arc Cutting
Using Taguchi Method. The focus on this project is to obtain an optimum condition (setting) to
obtain maximum MRR and minimum the surface roughness (SR).

A person doesn't need to be a physicist or chemist to understand the Plasma Arc Cutting (PAC)
and Gouging process. There are four states in which physical matter may be found: solid, liquid,
gas or plasma. Changes from one physical state to another occur, by either supplying or
subtracting energy, in the form of heat.

Water can be used as an example of these four states of matter. In the solid state it is ice at
temperatures of 0 degrees Celsius or colder. With the addition of heat the ice melts and changes
to water, the liquid state. The addition of more heat to temperatures of 212 degrees F. (100
degrees C.) or hotter) converts this liquid to its gaseous state, steam.

The fourth state of matter, plasma, looks and behaves like a high temperature gas, but with an
important difference; it conducts electricity. The plasma arc is the result of the electrical arcs
heating of any gas to a very high temperature so that its atoms are ionized (an electrically
charged gas due to an unequal number of electrons to protons) and enabling it to conduct
electricity. The major difference between a neutral gas and plasma is that the particles in plasma
can exert electromagnetic forces on one another.

If you happen to be reading this by the light emitted by a fluorescent lamp you see plasma in
action. Within the glowing tube of the lamp is plasma consisting of low pressure mercury or
sodium vapour. It is ionized by a high voltage across electrodes at the ends of the tube and
conducts an electric current which causes the plasma to radiate which in turn causes the
phosphor coating on the inner surface of the tube to glow.

For many years, oxy-acetylene cutting was often the process of choice for quickly cutting
through steel plate. Over the past few years plasma cutting has pretty much taken over, for some
very good reasons to perhaps most importantly. A plasma cutter will cut through any metal that
is electrically conductive. That means that one unit will cut steel, stainless steel, aluminium,
copper, bronze, and brass etc.

The plasma jet that does the cutting is hotter and narrower than an oxy-acetylene flame, so the
kerfs width is smaller, and can get cleaner cuts. This makes plasma cutting particularly well-
suited for cutting sheet metal, a task the oxy-acetylene cutting torch is not particularly well-

1
suited for since it leaves a lot of slag on the edges. The extremely tight focus of the plasma arc
tends to minimize heat distortion in the cut parts, as well.

1.2 WHAT IS PLASMA ?

One common description of plasma is that it is the fourth state of matter.We normally think of
the three states of matter as 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. As shown in figure
1.1 the temperature of ice cubes is 0 ˚C, the energy or heat is applied at about 100 ˚C and it
convert in to liquid. The more energy is applied to liquid at above 100 ˚C it converts in to gas.
The more energy applied to gas at about 10,000 ˚C it converts in to plasma state.

10,000
0
C
Above 100
0
C
100
0
0
0 C

Fig 1.1 Generation of plasma

1.3 IONISATION
If we add more energy to water, it vaporizes and separates into two gases, hydrogen and oxygen,
in the form of steam. By adding even more energy to a gas, we find that its characteristics are
modified substantially in terms of temperature and electrical characteristics. This process is
called ionisation, the creation of free electrons and ions among the gas atoms.

When this happens, the gas, which has now become a plasma, is electrically conductive because
free electrons are available to carry current. Many of the principles that apply to current
conduction through metals also apply to plasmas. For example, if the current-carrying cross-

2
section of a metal is reduced, the resistance increases. A higher voltage is needed to force the
same amount of electrons through this cross-section and the metal heats up. The same is true for
a plasma gas; the more we reduce the cross-section, the hotter it gets.

1.4 HISTORY AND DEVELOPMENT OF PLASMA ARC PROCESS

In 1941, the U.S. defence industry was looking for better ways of joining light metal together for
the war effort and, more specifically, for the production of airplanes. Out of this effort, a new
welding process was born. An electric arc was used to melt the metal, and an inert gas shield
around the arc and the pool of molten metal was used to displace the air, preventing the molten
metal from picking up oxygen from the air. This new process "TIG" (Tungsten Inert Gas),
seemed to be a perfect solution for the very specific requirement of high-quality welding. Since
this welding process became a substantial user of such gases as argon and helium, the industry
that had the most interest in this new application turned out to be the industrial gas
manufacturers. These industrial gas companies and, in particular, Union Carbide's Linde
Division, became active and successful with the TIG process, also known as "Argonarc" or
"Heliarc." Today, this process is referred to as "GTAW" (Gas Tungsten Arc Welding).

By 1950, TIG had firmly established itself as a new welding method for high-quality welds on
exotic materials. While doing further development work on the TIG process, scientists at Union
Carbide's welding laboratory discovered that when they reduced the gas nozzle opening that
directed the inert gas from the TIG torch electrode (cathode) to the workpiece (anode), the
properties of the open TIG arc could be greatly altered. The reduced nozzle opening constricted
the electric arc and gas and increased its speed and its resistive heat. The arc temperature and
voltage rose dramatically, and the momentum of the ionised and non-ionised gas removed the
molten puddle due to the higher velocity. Instead of welding, the metal was cut by the plasma jet.

In Figure, both arcs are operating in argon at 200 amps. The plasma jet is only moderately
constricted by the 3/16 inch (4.8 mm) diameter of the nozzle orifice, but it operates at twice the
voltage and produces a much hotter plasma arc than the corresponding TIG arc. If the same
current is forced through a nozzle with an even smaller opening, the temperature and voltage
rise. At the same time, the higher kinetic energy of the gas leaving the nozzle ejects the molten
metal, creating a cut.

3
 Fig 1.2 Temperature profiles for TIG arc and plasma jet (right)

The plasma cutting arc was considerably hotter than the TIG arc shown in Figure. These greater
temperatures were possible because the high gas flow in the plasma torch nozzle formed a
relatively cool boundary layer of un-ionised gas along the nozzle wall, allowing a higher degree
of arc constriction. The thickness of this boundary layer could be further increased by swirling
the cutting gas. The swirling action forced the heavier, cooler, un-ionised gas to move radially
outward and form a thicker boundary layer. Most plasma cutting torches swirled the cutting gas
to attain maximum arc constriction.

Fig 1.3 TIG welding arc

1.4.1 Transferred and Non-Transferred Modes

A plasma jet can be operated in the transferred mode, where the electric current flows between
the plasma torch electrode (cathode) and the workpiece (anode). It can also be operated in the
non-transferred mode where the electric current flows between the electrode and the torch
nozzle. Both modes of operation are illustrated in Figure.

4
 Fig 1.4 Transferred and non-transferred modes

Although a stream of hot plasma emerges from the nozzle in both modes of operation, the
transferred mode is invariably used in plasma cutting because the usable heat input to the
workpiece is more efficiently applied when the arc is in electrical contact with the workpiece.

1.4.2 Altering the Characteristics of the Plasma Jet

The characteristics of the plasma jet can be altered greatly by changing the gas type, gas flow
rate, arc current, arc voltage and nozzle size. For example, if low gas flow rates are used, the
plasma jet becomes a highly concentrated heat source ideal for welding. Conversely, if the gas
flow rate is increased sufficiently, the velocity of the plasma jet is so great that it ejects molten
metal created by the hot plasma arc and cuts through the workpiece.

1.4.3 Conventional Plasma Arc Cutting (1957)

The plasma jet generated by conventional "dry" arc constriction techniques was introduced in
1957 by Union Carbide's Linde Division. In the same year, Dr. Robert Gage obtained a patent,
which for 17 years gave Union Carbide a virtual monopoly. This technique could be used to
sever any metal at relatively high cutting speeds. The thickness of a plate could range from thin
sheet metal to plates as thick as ten inches (250 mm). The cut thickness was ultimately
dependent on the current-carrying capacity of the torch and the physical properties of the metal.
A heavy duty mechanized torch with a current capacity of 1000 amps could cut through 10-inch
thick stainless steel and aluminium. However, in most industrial applications, plate thickness
seldom exceeded two inches. In this thickness range, conventional plasma cuts were usually
bevelled and had a rounded top edge. Bevelled cuts were a result of an imbalance in the heat
input into the cut face. A positive cut angle resulted because the heat energy at the top of the cut
dissipated as the arc progressed through the cut.

This heat imbalance was reduced by placing the torch as close as possible to the workpiece and
applying the arc constriction principle, as shown in Figure. Increased arc constriction caused the
temperature profile of the electric arc to become extended and more uniform. Correspondingly,

5
the cut became more square. Unfortunately, the constriction of the conventional nozzle was
limited by the tendency of increased constriction to develop two arcs in series, one arc between
the electrode and nozzle and a second arc between the nozzle and workpiece.

This phenomenon was known as "double arcing" and damaged both the electrode and nozzle.
Double arcing severely limited the extent to which plasma cut quality could be improved. Since
the introduction of the plasma arc process in the mid-50's, considerable research has focused on
increasing arc constriction without creating double arcing. Plasma arc cutting as performed then
is now referred to as "conventional plasma cutting." It can be cumbersome to apply if the user is
cutting a wide variety of metals and different plate thicknesses. For example, if the conventional
plasma process is used to cut stainless steel, mild steel, and aluminium, it is necessary to use
different gases and gas flows for optimum cut quality on all three metals.

Conventional plasma cutting predominated from 1957 to 1970, and often required very
expensive gas mixtures of argon and hydrogen.

1.4.4 Dual Flow Plasma Arc (1962)

The dual flow technique was developed and patented by Thermal Dynamics Corporation and
James Browning, President of TDC, in 1963. It involved a slight modification of the
conventional plasma cutting process. Essentially, it incorporated the same features as
conventional plasma cutting, except that a secondary gas shield was added around the plasma
nozzle. Usually, in dual flow operation the cutting, or plasma, gas was nitrogen and the
secondary shielding gas was selected according to the metal to be cut. Secondary shield gases
typically used were air or oxygen for mild steel, carbon dioxide for stainless steel, and an
argon/hydrogen mixture for aluminium.

Cutting speeds were still better than with conventional cutting on mild steel; however, cut quality
was inadequate for many applications. Cutting speeds and quality on stainless steel and
aluminium were essentially the same as with the conventional process.

The major advantage of this approach was that the nozzle could be recessed within a ceramic gas
cup or shield cup as shown in Figure 4, preventing the nozzle from shorting with the workpiece,
and reducing the tendency for double arcing. The shield gas also covered the cutting zone,
improving cut quality and speeds as well as cooling the nozzle and shield cap.

6
 Fig 1.5 Dual flow plasma cutting

1.4.5 Air Plasma Cutting (Since 1963)

Air cutting was introduced in the early 1960s for cutting mild steel. The oxygen in the air
provided additional energy from the exothermic reaction with molten steel. This additional
energy increased cutting speeds by about 25% over plasma cutting with nitrogen. Although the
process could be used to cut stainless steel and aluminium, the cut surface on these materials was
heavily oxidized and unacceptable for many applications.

The biggest problem with air cutting has always been the rapid erosion of the plasma torch
electrode. Special electrodes, made of zirconium, hafnium, or hafnium alloy, were needed since
tungsten eroded in seconds if the cutting gas contained oxygen. Even with these special
materials, electrode life using air plasma was much less than the electrode life associated with
conventional plasma.

Although air cutting was not pursued in the late 1960s in the United States and the western
world, steady progress was made in eastern Europe with the introduction of the "Feinstrahl
Brenner" (torch producing a restricted arc), developed by Manfred van Ardenne. This technology
was adopted in Russia and eventually in Japan. The major supplier became Mansfeld of East
Germany. Several shipyards in Japan were early users of air plasma cutting equipment. However,
the electrode life was relatively short and studies disclosed that the cut face of the workpiece had
a high percentage of nitrogen in solution which could cause porosity when subsequently welded.

1.4.6 Water Shield Plasma Cutting (1965)

Water shield plasma cutting was similar to dual flow except that water was substituted for the
shield gas. Cut appearance and nozzle life were improved because of the cooling effect provided
by the water. Cut squareness, cutting speed and dross accumulation were not measurably
improved over dual flow plasma cutting because the water did not provide additional arc
constriction.

7
1.4.7 Water Injection Cutting (1968)
Earlier, it was stated that the key to improving cut quality was increasing arc constriction while
preventing double arcing. In the water injection plasma cutting process, water was radially
injected into the arc in a uniform manner as shown in Figure 5. The radial impingement of the
water at the arc provided a higher degree of arc constriction than could be achieved by just the
copper nozzle alone. Arc temperatures in this region are estimated to approach 50,000°K or
roughly nine times the surface temperature of the sun and more than twice the temperature of the
conventional plasma arc. The net result was improved cut squareness, increased cutting speeds
and the elimination of dross when cutting mild steel. Radial water injection arc constriction was
developed and patented in 1968 by Richard W. Couch Jr., President of Hypertherm, Inc.

Fig 1.6 Water injection plasma cutting.

Another approach taken to constrict the arc with water was to develop a swirling vortex of water
around the arc. With this technique, the arc constriction was dependent on the swirl velocity
needed to produce a stable water vortex. The centrifugal force created by the high swirl velocity
tended to flatten the annular film of water against the arc and, therefore, achieved less of a
constricting effect than with radial water injection.

Unlike the conventional process described earlier, optimum cut quality with water injection
plasma was obtained on all metals with just one gas: nitrogen. This single gas requirement made
the process more economical and easier to use. Physically, nitrogen was ideal because of its
superior ability to transfer heat from the arc to the workpiece. The heat energy absorbed by
nitrogen when it dissociated was relinquished when it recombined at the workpiece. Despite the
extremely high temperatures at the point where the water impinged the arc, less than 10% of the
water was vaporized. The remaining water exited from the nozzle in the form of a conical spray,
which cooled the top surface of the workpiece. This additional cooling prevented the formation
of oxides on the cut surface and efficiently cooled the nozzle at the point of maximum heat load.

The reason for arc constriction at the zone of water injection was the formation of an insulating
boundary layer of steam between the plasma jet and the injected water. (This steam boundary

8
layer, the "Linden Frost Layer," is the same principle that allows a drop of water to dance around
on a hot metal plate rather than immediately vaporizing.)

Nozzle life was greatly increased with the water injection technique because the steam boundary
layer insulated the nozzle from the intense heat of the arc, and the water cooled and protected the
nozzle at the point of maximum arc constriction and maximum arc heat. The protection afforded
by the water steam boundary layer also allowed a unique design innovation: the entire lower
portion of the nozzle could be ceramic. Consequently, double arcing, a major cause of the nozzle
destruction was virtually eliminated.

An important characteristic of the cut edges was that the right side of the kerf was square and the
left side of the kerf was slightly beveled. This was not caused by water injection but rather it
resulted from the clockwise swirl of the plasma gas. This swirl caused more arc energy to be
expended on the right side of the kerf. This same cut asymmetry existed using the conventional
"dry" cutting when the cutting gas was swirled. This meant that the direction of travel needed to
be properly selected to produce a square cut on the correct side of the workpiece.

In the case of cutting a ring with parallel sides, the outer radius would be cut in the clockwise
direction, which gives a square cut on the right side. Similarly, the inside cut is made in a
counterclockwise direction to maintain a square edge on the inside of the ring. A
counterclockwise swirl ring can be provided which reverses the gas flow swirl and,
consequently, also the good side of the cut to the left side. This would be used if a two torch
cutting system had to cut mirror image parts simultaneously.

1.4.8 Water Muffler and Water Table (1972)

Since the plasma arc process was a highly concentrated heat source of up to 50,000K, there were
some negative side effects with which to contend:

1. At highest arc current, plasma cutting generated an intense noise level well over that
normally allowed at work areas, requiring ear protection.
2. Smoke and potentially toxic gas developed at the work area, requiring good ventilation.
3. Ultraviolet radiation, which could potentially lead to skin and eye burns, required
protective clothing and dark glasses.

These side effects opened the plasma arc process to criticism on the environmental front.
Something had to be found to deal with these problem areas.

In 1972, Hypertherm introduced and patented the Water Muffler and the Water Table Pollution
Control systems, which controlled the potentially hazardous effects of plasma arc cutting.

9
Water Muffler
The Water Muffler system created a high flow water shield around the torch which produced the
following benefits when used with a Water Table:

1. The high noise level of the plasma arc was sharply reduced through the muffling effect of
the water curtain.
2. Smoke and toxic gases were confined to the area of the water curtain, which acted as a
water scrubber, removing the smoke particles in the water.
3. Arc glare was reduced to a level that was less dangerous to the eyes.
4. With the proper dye in the water, ultraviolet radiation was diminished.

Water Table
The water reservoir of the Water Table located beneath the workpiece encapsulated the high
intensity noise from escaping out the bottom of the cut and also absorbed smoke particles.

1.4.9 Underwater Cutting (1977)

Further attempts in Europe to decrease the noise level of the plasma arc and to eliminate smoke
development as much as possible led to underwater cutting. This method for high power plasma
cutting with cutting currents above 100 amps has become so popular that today, many high
power plasma cutting systems cut under water.

For underwater plasma cutting, the workpiece is immersed about 2 to 3 inches under water and
plasma torch cut while immersed in the water. The smoke and noise level as well as the arc glare
are reduced dramatically. One negative effect of this cutting method is that the workpiece can not
be observed while cutting and the cutting speed is reduced by 10-20%. Further, the operator can
no longer determine from the arc sound whether the cutting process is proceeding correctly and
whether the consumables are producing a good quality cut.

Finally, when cutting in water, some water surrounding the cut zone is disassociated into oxygen
and hydrogen, and the freed oxygen has a tendency to combine with the molten metal from the
cut (especially aluminium and other light metals) to form metal oxide, which leaves free
hydrogen gas in the water. When this hydrogen collects in a pocket under the workpiece, it
creates small explosions when reignited with the plasma jet. Therefore, the water needs to be
constantly agitated while cutting such metals.

1.4.10 Underwater Muffler

Based on the popularity of underwater cutting, in 1986 Hypertherm designed and patented an
underwater Water Muffler which injected air around the torch, establishing an air bubble in
which cutting could proceed. This became the air injected underwater cutting process which is

10
most often used with oxygen cutting up to 260 amps. Use of this process increased cut quality
and produced normal high cutting speeds achieved by water-line and "in-air" plasma cutting
techniques.

1.4.11 Low-Amp Air Plasma Cutting (1980)

In 1980, plasma arc cutting equipment manufacturers in the Western hemisphere introduced
equipment using air as the plasma gas, particularly for low-amp plasma systems. By early 1983,
Thermal Dynamics launched the PAK3 and SAF introduced the ZIP-CUT. Both units were
immensely successful, one in the USA and the other in Europe. This opened a new era for
plasma arc cutting which increased the world market size about 50 times in the 1980s and
created many new manufacturers. Plasma arc cutting was finally accepted as the new method for
metal cutting and considered a valuable tool in all segments of the modern metalworking
industry.

With the new thrust given to the plasma arc cutting industry through increased competition,
many new improvements were introduced which made the process easy to use. The process was
much more reliable and required less skill to operate. Power supply designs using solid state
primary and secondary converter technology improved arc characteristics and reduced the size
and weight of the systems. Hypertherm made other contributions with such patents as the
blowback (or contact start) torch which eliminated high frequency arc starting, and the air-
injected shield nozzle, which protected front end parts during metal piercing.

1.4.12 Oxygen Plasma Cutting (1983)

Since the traditional method of cutting steel was the oxyfuel process, it was logical that engineers
that developed plasma arc cutting tried from the very beginning to use oxygen as the plasma gas.
However, the very high temperatures at the tip of the electrode and the presence of pure oxygen
caused all known electrode materials to rapidly deteriorate, so either no cuts could be made or
only cuts of a very short duration This rendered oxygen and air unacceptable as plasma gases.
Oxygen cutting therefore was abandoned in the early years of plasma cutting technology
development. In early 1970, it was found that hafnium and zirconium in an industrially available
form did resist the rapid deterioration which occurred with oxygen plasma arc cutting. Air and
oxygen as plasma gases again became of extreme interest.

Hypertherm took this challenge and began R & D efforts in earnest. In 1983, the company
succeeded with an improved torch design that made it possible to use oxygen as the plasma gas.
A patent for water-injected oxygen plasma arc cutting was granted and oxygen plasma cutting
became the latest development in plasma arc technology. Oxygen plasma cutting offered a wide
range of dross-free cutting speed conditions, increased cutting speed by up to 30%, while
operating at lower current levels, and produced smooth, square, and softer edges. The resulting

11
cut edge was easier to fabricate by bending or welding. All steels, including high strength, low
alloy steels, were now cut dross free with this new process.

The critical part continued to be electrode life, which, even when using hafnium, remained
limited. However, the cut quality of steel cut with oxygen was superb, and most end users found
the tradeoff of much higher speed and cut quality in the face of shorter electrode life to be
acceptable. Costly post-cut dross removal operations often associated with nitrogen cutting were
virtually eliminated with oxygen plasma.

1.4.13 Oxygen Injection Plasma Cutting (1985)

Oxygen injection plasma cutting circumvented the electrode life problem by using nitrogen as
the plasma gas and injecting oxygen downstream at the exit of the nozzle as shown in Figure 6.

Fig 1.7 Oxygen injection plasma cutting.

This process was used exclusively on mild steel and slightly increased the cutting speeds.
However, major disadvantages were lack of cut squareness, excessive kerf removal, short nozzle
life, and limited versatility (mild steel). While this process is still being used at some locations,
the limited increase in performance associated with it does not justify the extra expense of this
rather complicated and delicate torch design.

1.4.14 Deep Water Plasma Cutting

In the 1990s, the atomic power industry was faced with two major challenges:

1. How to extend the life of existing nuclear plants

2. How to dismantle non-operational plants

While the power industry is working hard to develop procedures for repairing components in the
reactor pool, the atomic commissions of several countries are searching for methods to cut the
expended reactors and other components into small pieces for disposal.

12
Since the reactor and auxiliary components must be kept in a pool of water, all repair and
dismantling must also he done underwater. Since a major part of the components are made of
stainless steel, plasma cutting is a desired method. Overcoming the problems of underwater
cutting has been a challenge to plasma equipment manufacturers with most refusing to get
involved in the process. Hypertherm has worked with several contractors in the nuclear power
industry to develop plasma cutting equipment for underwater cutting. In 1990 Hypertherm's
PAC500 1000 amp plasma system was successfully used to cut up 4 1/2" (114 mm) stainless
steel heat shields under 15 feet (4.56 m) of water at the Connecticut Yankee Nuclear power
plant. Also in 1990, the MAX100 and MAX200 were used underwater in several locations at a
depth of 25 feet (7.62 m). Plans are being made to cut below 100 feet (30.48 m) for offshore
applications.

1.4.15 High Density Plasma Cutting (1990)

Laser cutting has become an important competitor in the metal-cutting industry because of its
ability to produce high quality cuts with precise accuracy. To assume a place in the precision
metal-cutting market, plasma equipment manufacturers have increased their design efforts to
further improve the cut quality of their equipment.

In the early 1990s we saw the first high quality plasma installation of 40 to 90 amps, which
produced a squarer cut and reduced kerf width with increased cutting speed. Some units have
come from Japanese manufacturers. Hypertherm has introduced its HyDefinitiontechnology to
compete in this marketplace. The expectations are that a plasma cut will soon be of the same
quality as a laser cut. Since plasma equipment is much lower in capital cost than a laser unit, we
expect that this type of plasma cutting will become a major competitor in today's laser cutting
market.

1.4.16 Laser Lasting Consumable Parts (1990)

Since air and oxygen plasma cutting have become more popular, the major issue has become the
short life cycle of their consumable parts. The major manufacturers of plasma cutting systems
are working on this issue. It is expected in the near future that the lifetime of air/oxygen
electrodes will be extended substantially, reducing the cost of plasma cutting, and thereby
making this process much more widely used for cutting steels. Hypertherm has introduced
its LongLife technology on several models which offer greatly increased parts life.

1.5 INTRODUCTION OF CNC PLASMA CUTTING MACHINE

Plasma cutting technology is one in which argon, nitrogen and compressed air are used to
produce a plasma jet and then they are used to cut nonferrous metal, stainless steel and black
metal by the high temperature of the highly compressed plasma arc and the mechanical erosion
of the first plasma jet.

13
This technology has developed since this its introduction in the 1990s to complete with flame
cutting process for thick plates and lesser cutting technology for thin plates. It has recently been
used widely for process of irregular cutting, rough machining and structure component stocking
in shipbuilding industry, machine manufacturing industry and so on. The CNC plasma cutting
machine is shown in figure.

Fig 1.8 CNC Plasma cutting machine

(At. GUJARAT APOLLO EQUIPMENTS LTD., DHOLASAN)

1.6 PRINCIPLE OF PLASMA CUTTING MACHINE

As shown in figure the HF contact type uses a high-frequency, high voltage spark to ionize the
air through the torch head and initiate an arc of plasma torch. These require the torch to be in
contact with the job material when starting, and so are not suitable for applications involving
computer numerical controlled (CNC) cutting.

The Pilot Arc type uses a two cycle type approach to producing plasma, avoiding the need for
initial contact. First a high voltage, low current circuit is used to initialize a very small high
intensity spark within the torch body, there by generating a small pocket of plasma gas. This is
referred to as the pilot arc. The plasma is additionally coupled by a water cooled nozzle for
cooling purpose. With this energy, densities up to 2x106 W/cm2 inside of the plasma beam can
be achieved. The pilot arc has a return electrical path built into the torch head. The pilot arc will

14
Maintain itself 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 25000 °c.

Fig 1.9 Principle of plasma cutting machine

Plasma is an effective means of cutting thin and thick materials equally hand –held torches can
usually cut up to 2 inches thick steel plate and stronger computer-controlled torches can cut steel
up to 6 inches thick plate. Since plasma cutters generate a very hot and much localized “cone” to
cut thin thick plate. They are extremely useful for cutting sheet metal in curved, angled shapes
and combined both of it.

1.7 PROCESS DESCRIPTION

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 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.

15
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 aluminum and stainless steel form an oxide that inhibits further oxidization, making
conventional oxy fuel cutting impossible. Plasma cutting, however, does not rely on oxidation to
work, and thus it can cut aluminum, 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 oxy fuel cutting. However, for heavy sections of steel, oxy fuel is still
preferred since oxy fuel is typically faster and, for heavier plate applications, very high capacity
power supplies are required for plasma cutting applications.

The power source and arc starter circuit are connected to the torch via interconnecting leads and
cables.These leads and cables supply the proper gas flow, electrical current flow and high
frequency to the torch to start and maintain the process.

16
A start input signal is sent to the power supply. This simultaneously activates the open circuit
voltage and the gas flow to the torch (see Figure)

Fig 1.10 While the metal to be cut (work piece) is connected directly to positive. Gas flows
through the nozzle and exits out the orifice. There is no arc at this time as there is no
current path for the DC voltage.

Open circuit voltage can be measured from the electrode (-) to the nozzle (+). Notice that the
nozzle is connected to positive in the power supply through a resis0tor and a relay (pilot arc
relay)

After the gas flow stabilizes, the high frequency circuit is activated. The high frequency breaks
down between the electrode and nozzle inside the torch.

Fig 1.11 It is done in such a way that the gas must pass through this arc before exiting the
nozzle.

17
Energy transferred from the high frequency arc to the gas causes the gas to become ionized,
therefore electrically conductive. This electrically conductive gas creates a current path between
the electrode and the nozzle, and a resulting plasma arc is formed. The flow of the gas forces this
arc through the nozzle orifice, creating a pilot arc. Assuming that the nozzle is within close
proximity to the work piece, the pilot arc will attach to the work piece, the current will start
flowing as the current path to positive is not restricted.

Fig 1.12 Current flow to the work piece is sensed electronically now the high frequency is
disabled and the pilot arc relay is opened. Gas ionization is maintained with energy from
the main DC arc.

The temperature of the plasma arc melts the metal, pierces through the work piece and the high
velocity gas flow removes the molten material from the bottom of the cut kerf.

Fig 1.13 At this time, torch motion is initiated and the cutting process begins.

18
1.8 SHIELDING AND CUTTING GASES FOR PLASMA CUTTING

Inert gases such as argon, helium, and nitrogen (except at elevated temperatures) are used with
tungsten electrodes. Air may be used for the cutting gas when special electrodes made from
water-cooled copper with inserts of metals such as hafnium are used. Recently, PAC units
shielded by compressed air have been developed to cut thin-gauge materials.

Almost all plasma cutting of mild steel is done with one of three gas types:

1. Nitrogen with carbon dioxide shielding or water injection (mechanized)

2. Nitrogen-oxygen or air
3. Argon-hydrogen and nitrogen-hydrogen mixtures

The first two have become standard for high-speed mechanized applications. Argon hydrogen
and nitrogen-hydrogen (20 to 35 percent hydrogen) are occasionally used for manual cutting, but
the formation of dross, a tenacious deposit of resolidifide metal attached at the bottom of the cut,
is a problem with the argon blend. A possible explanation for the heavier, more tenacious dross
formed with argon is the greater surface tension of the molten metal.

The surface tension of liquid steel is 30 percent higher in an argon atmosphere than in one of
nitrogen. Air cutting gives dross similar to that formed in a nitrogen atmosphere. The plasma jet
tends to remove more metal from the upper part of the work piece than from the lower part. This
results in nonparallel cut surfaces that are generally wider at the top than at the bottom. The use
of argon-hydrogen, because of its uniform heat pattern or the injection of water into the torch
nozzle (mechanized only), can produce cuts that are square on one side and beveled on the other
side. For base metal over 3 inches thick, argon-hydrogen is frequently used without water
injection.

1.9 PLASMA GAS SELECTION

1.9.1 Air Plasma

 Mostly used on ferrous or carbon based materials to obtain good quality a faster cutting
speeds.
 Only clan, dry air is recommended to use as plasma gas. Any oil or moisture in the air
supply will substantially reduce torch parts life.
 Air Plasma is normally used with air secondary.

19
1.9.2 Nitrogen Plasma

 Can be used in place of air plasma with air secondary.

 Provides much better parts life than air Provides better cut quality on non-ferrous
materials such as stainless steel and aluminum.
 A good clean welding grade nitrogen should be used.

1.9.3 Argon/Hydrogen Plasma

 A 65% argon/35% hydrogen mixture should be used.

 Recommended use on 19mm and thicker stainless steel. Recommended for 12mm and
thicker non-ferrous material.
 Ar/H2 is not normally used for thinner non-ferrous material because less expensive gases
can achieve similar cut quality.
 Provides faster cutting speeds and high cut quality on thicker material to offset the
higher cost of the gas.
 Poor quality on ferrous materials.

1.9.4 Oxygen Plasma

 Oxygen is recommended for cutting ferrous metals.

 Provides faster cutting speeds.
 Provides very smooth finishes and minimizes nitride build-up on cut surface (nitride
build-up can cause difficulties in producing high quality welds if not removed).

1.10 SECONDARY GAS SELECTION FOR PLASMA CUTTING

1.10.1 Air Secondary

 Air secondary is normally used when operating with air plasma and occasionally with
nitrogen plasma.
 Inexpensive - reduces operating costs.
 Improves cut quality on some ferrous materials.

1.10.2 CO2 Secondary

 CO2 secondary is used with nitrogen or Ar/H2 plasma.

 Provides good cooling and maximizes torch parts life.
 Usable on any ferrous or non-ferrous material.
 May reduce smoke when used with Ar/H2 plasma.

20
 Table 1.1 SUMMARY TABLE FOR GAS SELECTION

MATERIAL
MATERIAL
GAS CARBON STAINLESS
THICKNESS ALUMINIUM
STEEL STEEL
Air Plasma Gage Good/Excellent Good/Excellent Good/Excellent
Air Gage to 12 mm Excellent Good Good
Secondary 12 mm and Up Excellent Fair Fair
Nitrogen Gage Good/Excellent Good/Excellent Good/Excellent
Plasma
Air Gage to 12 mm Good/Excellent Good/Excellent Good/Excellent
Secondary or 12 mm and Up Good/Excellent Good/Excellent Good/Excellent
CO2
Secondary
Ar/H2 Gage to 6 mm NR NR NR
Plasma
N2 or CO2 6 mm to 30 mm NR Good Excellent
Secondary 12 mm and Up NR Good/Excellent Excellent

1.11 SYSTEM
Plasma arc cutting can increase the speed and efficiency of both sheet and plate metal cutting
operations. Manufacturers of transportation and agricultural equipment, heavy machinery,
aircraft components, air handling equipment, and many other products have discovered its
benefits. Basically Plasma Arc Cutter comprises of 8 major parts such as air compressor, AC
plug, power supply, plasma torch, ground clamp, electrode, nozzle and work piece. The plasma
arc cutting system shown in figure.

Fig 1.14 Plasma Arc Cutter System

21
1.12 PLASMA TORCH

The Plasma cutting process is used with 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 mechanized 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
adjustment 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.

1.13 TORCH CONSUMABLES

The plasma torch is designed to generate and focus the plasma cutting arc. In machine torches,
the parts are used: an electrode to carry the current form the power source, a swirl ring to spin the
compressed air, a nozzle that constricts and focuses the cutting arc, and a shield and retaining
ring to protect the torch. Torch consumables are shown in figure.

22
 Water tube

Electrode

Swirl ring

Nozzle

Retaining cap

Shield

Shield cap

Fig 1.15 Assembly of torch consumables

1.13.1 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). The electrode is shown in figure.

Fig 1.16 Electrode

23
1.13.2 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 centers the arc
on the electrode and helps to control and constrict the arc as it passes through the nozzle.
The swirl ring for hypertherm HPR 150 torch is shown in figure.

Fig 1.17 Swirl ring

1.13.3 Nozzle

The purpose of the torch nozzle is to constrict and focus the plasma arc. Constricting the arc
increases the energy density and velocity. The nozzle is made of copper, with a specifically sized
hole or orifice in the centre of the nozzle. Nozzle is sized according to the amperage rating of the
torch that they are to be used in. Nozzle use in plasma cutting machine is shown in figure.

Fig 1.18 Nozzle

24
1.14 PLASMA TORCH CONSUMABLES SPECIFICATION FOR
DIFFERENT MATERIAL

FOR MILD STEEL

Shield Nozzle Swirl Water

Ampere Shield Nozzle Electrode
cap retaining cap ring tube

30 A 220173 220194 220313 220193 220180 220192 220340

50A 220173 220555 220313 220554 220553 220552 220340

80A 220173 220189 220176 220188 220179 220187 220340

130A 220173 220183 220176 220182 220179 220181 220340

Table1.2 Plasma torch consumables specification for mild steel

FOR STAINLESS STEEL

Shield Nozzle Swirl Water

Ampere Shield Nozzle Electrode
cap retaining cap ring tube

45 A 220173 220202 220304 220201 220180 220308 220340

80 A 220173 220338 220304 220337 220179 220339 220340

130 A 220173 220198 220304 220197 220179 220307 220340

Table1.3 Plasma torch consumables specification for stainless steel

FOR ALUMINUM

Shield Nozzle Swirl Water

Ampere Shield Nozzle Electrode
cap retaining cap ring tube

45 A 220173 220202 220176 220201 220180 220308 220340

130 A 220173 220198 220304 220197 220179 220307 220340

Table1.4 Plasma torch consumables specification for aluminum

25
1.15 INTRODUCTION TO PROBLEM

Advanced materials exhibit very excellent technical properties. However, the high cost of both
raw materials and processing limit their use. Alternatively, advanced machining such as Plasma
Arc Cutting is normally used. Advanced material such as nickel-base alloys, titanium alloys and
stainless steel can be used as the work piece in this type of cutting.

A torch in which temperatures as high as 30,000°C are achieved by injecting a plasma gas
tangentially into an electric arc formed between electrodes in a chamber; the resulting vortex of
hot gases emerges at very high speed through a hole in the negative electrode, to form a jet for
welding, spraying of molten metal, and cutting of hard rock or hard metals.

The plasma arc also cuts ferrous and non-ferrous metals much faster than an Oxy-Fuel torch or
abrasive saws, with low or no heat affected zone, especially on thinner metals. A clean cut with
little or no dross means less time and money is required to finish the work piece. Parts are
virtually weld-ready.

With plasma cutting, less preparation work is required. A plasma arc is hot enough to burn
through most surface coatings such as paint and rust and still provides excellent cutting results.
With plasma cutting, there is minimal heat input and distortion of the metal as there is with
jigsaws or cutting shears. For applications where difficult shapes are being handled or cut, such
as ventilation ductwork (HVAC), tanks or vessels, plasma cutting offers considerable advantage
since no fixturing is required.

The feasibility and effectiveness needs to be proven by experiment and by using Taguchi Method
of the processing parameter to obtain the best factors combination (MRR and Surface
Roughness).

1.16 PROBLEM STATEMENT

Plasma arc cutting can be characterized in terms of two distinct speeds. At cutting speeds above,
the plasma jet does not cut through metal plate. At speeds below, the molten metal from the kerf
sticks to the bottom of the plate, forming the so-called dross and how to properly select a plasma
cutting system. Plasma can cut in a wide range of cutting parameters (currents, metal thicknesses
and nozzle orifice diameters) for plasma arc cutting of stainless steel materials.

The plasma arc cutting process employs a plasma torch with a very narrow bore to produce a
transferred arc to the work piece at an average current density of within the bore of the torch.
The energy and momentum of the high-velocity plasma jet generated by the plasma torch melts,

26
vaporizes and removes the metal from the region of impingement of the nozzle. Others problem
is:

a. What type of metal is to cutting?

b. What is primary input power when cutting process?
c. How thick is the metal want to cut?
d. Traditional way of cutting takes a lot of time.
e. The effective way to conduct the cutting process for Stainless Steel.
f. The most important factors that influence the cutting process?
g. What are the best conditions to achieve optimum performances?

1.17 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 Mild Steel / Hardrox /
BQ / ST52 / SAILMA

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).

1.18 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 Mild Steel / Hardrox / BQ / ST52 / SAILMA.

3. Design of Experiments (DOE) layout will be used for testing and analyzing.

4. All of data was analyzed by using Minitab 16 Software to produce the best combination
setting in plasma cutting for Mild Steel / Hardrox / BQ / ST52 / SAILMA.

5. The machine used will Messer CNC plasma cutting machine.

27
1.19 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 full
factorial method by Minitab 16 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.

1.20 SUMMARY

In this chapter we have described, Introduction of CNC Plasma Cutting Machine, History and
Development of Plasma Arc Process, Principle of Plasma Cutting Machine, Process Description,
Shielding and Cutting Gases for Plasma Cutting, Plasma Gas Selection, Secondary Gas Selection
for Plasma Cutting, System, Plasma torch, Torch consumables, Plasma torch consumables
specification for Different material. Next chapter is on literature review of different laser
engraving process, with different optimization technique on different smaterial are discussed.

28
 CHAPTER 2
LITERATURE REVIEW

2.1 Introduction
Literature review provides the scope for the present study. It works as guide to run this
analysis. Literature review plays important role to get information about the dissertation work.
Literature includes different study on plasma arc cutting processes for better surface finish with
by using parametric analysis, and effect of cutting speed, arc current, gas pressure and other so
many parameters also effect on surface finish and material removal rate.

2.2 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 high-
temperature 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.

29
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.

30
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 high-
alloy 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

31
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 multi-
responses 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.

32
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.

33
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

34
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

35
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.

36
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

37
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.

2.3 Identified Gaps In the Literature

From the above literature review it is concluded that work was done on plasma arc cutting of
different material like Hardrox-400, EN31 steel, AISI 304, ST52, ST37, pure titanium, AISI
6061 aluminium alloy, ceramic, ISO Fe510, MS, etc but less work done on SAILMA material by
PAC process. And also it found that there is no attention paid on optimization of plasma arc
cutting process parameter on SAILMA materials by grey relational analysis. So finally it decides
to work on optimization of plasma arc cutting process parameters of SAILMA using full factorial
method, ANOVAs analysis and grey relational analysis.

2.4 Summary

Literature review for Experimental investigation of plasma arc cutting process and optimization
of the same is described above which help to understand different process parameters related to
plasma arc cutting process. It also helps to understand the importance of Grey Relational
Analysis for the optimization for the plasma arc cutting process. In next chapter we have
discussed about design of experiment.

38
 CHAPTER 3
DESIGN OF EXPERIMENT

3.1 Introduction of Parameter

In this dissertation work process parameters considered for plasma arc cutting are cutting
speed, arc current and gas pressure and response variables considered which to be
measures are surface roughness and material removal rate. These are shown in Table 3.1.

Table 3.1 Process parameters and response variables

Process Parameters Response Variables
Cutting Speed (mm/min) Surface roughness (µm)
Arc Current (amp) Material removal rate (gms/sec)
Gas Pressure (kgf/cm2) -

There are some fix variables in plasma arc cutting process, which is shown in Table 3.2.

Table 3.2 Fixed variables

Sr. No. Fixed Variables

1 Work material
(SAILMA)
2 Sample Dimensions
(100mm × 100 mm × 6 mm)

3.2 DESIGN FACTORS

Design of Experiments technique has been utilized to obtain the best combination of
design factors to achieve optimum performance measures. Plasma Arc Cutting involves
several input parameters to be considered during machining process. In this thesis, the
combination factors such as Cutting Speed [mm/min], Current Flow Rate [amp] and Gas
Pressure [kgf/cm2] are considered. These factors are the most important to have the best
value for Surface Roughness (Ra) and Material Removal Rate (MRR) when cutting
material like SAILMA.

3.2.1 Process parameters

3.2.1.1 Cutting Speed

The best way to judge cutting speed is to look at the arc as it exits the bottom of the work
piece. Observe the angle of the cutting arc through the proper welding lens. If cutting with
air, the arc should be vertical straight down, or zero degrees as it exits the bottom side of
the cut. If cutting with nitrogen or argon/hydrogen, then the correct cutting speed will
produce a trailing arc (that is, an exit arc that is opposite to the direction of torch travel).

39
The torch speed needs to be adjusted to get a good-quality cut. A cutting speed that is too
slow or too fast will cause cut quality problems. In most metals there is a window between
these two extremes that will give straight, clean, dross free cuts.
For this dissertation work cutting speed is considered the range between 2850-4050
mm/min.

3.2.1.2 Arc Current

Arc Current is the value of current given during cutting process. The cause of the burn-
through was the increase in the cutting current or the decrease in the cutting speed. When
the cutting current increases or the cutting speed decreases, the stable state of the keyhole
changes accordingly. If the cutting current and the flow rate of the plasma gas are
increased and/or the cutting speed is decreased, the process will withstand larger variations
in the cutting parameters.

For this dissertation work Arc Current is considered the range between 80amp and
130amp.

3.2.1.3 Gas Pressure

According to Larry Jeffus, “Principle and Application of Welding” Sixth Addition, almost
any gas or gas mixture can be used today for the PAC process. Normally Nitrogen or
Argon with 0-35% Hydrogen is used for cutting Stainless Steel material. We used O2 for
our experiment purpose. It is important to have the correct gas flow rate for the size tip,
metal type and thickness. Too low a gas flow will result in a cut having excessive dross
and sharply bevelled sides. Too high a gas flow will produce a poor cut because of
turbulence in the plasma stream and waste gas. Controlling the pressure is one way of
controlling gas flow.

For this dissertation work gas pressure is considered the range between 80-120 kgf/cm2.

3.2.2 Response variables

3.2.2.1 Surface roughness

Roughness is a measure of the texture of a surface. It is quantified by the vertical

deviations of a real surface from its ideal form. If these deviations are large, the surface is
rough; if they are small the surface is smooth. Roughness is typically considered to be the
high frequency, short wavelength component of a measured surface. Surface roughness
normally measured.
Roughness plays an important role in determining how a real object will interact with its
environment. Rough surfaces usually wear more quickly and have higher friction
coefficients than smooth surfaces (see tribology). Roughness is often a good predictor of

40
the performance of a mechanical component, since irregularities in the surface may form
nucleation sites for cracks or corrosion.
In this thesis, the average surface roughness is measured and calculated. Surface
roughness will be measures by surface roughness tester.

3.2.2.1 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 [gms/sec]

Where, WRW: work piece removal weight (gms)

T: cutting time (sec)

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 (gms/ mm3)

3.3 Design of Experiment

3.3.1 Introduction

In industry, designed experiments can be used to systematically investigate the process or

the product variables that influence the product quality. In design of experiments, the
experimenter is often interested in the effect of some process or investigation. Increasing
productivity and improving quality are important goal in any business. The method for
determining how to increase productivity and improving quality are evolving. The design
of experiments (DOE) is an efficient procedure for planning experiments so
that the obtained data can be analyzed to yield valid and objective conclusions.
DOE begins with determining the objectives of an experiment and selecting the process
factors for the study. An Experimental Design is the laying out of a detailed experimental
plan in advance of doing the experiment.

The word experiment is used in a quite precise sense to mean an investigation where the
system under study is under the control of the investigator. This means that experiment is
the process in which purposeful changes are made to the input variables of process or
systems, so that we may observe and identify the reasons for changes that may be
observed in the output response. For investigate or discovers something about any
process there are number of experiments are required for finding response of desire output
in condition of large input. Therefore to reduce the number of Experiments and to obtain

41
good quality of investigation the term named Design of experiments (DOE) is highly
useable method in all over the world.

The purpose of design of experiment is to plan, design and analyze the experiment so that
the valid and objective conclusions can be drawn effectively and efficiently.

3.3.2 Phases of design of experiment

1) Planning

It is important to carefully plan for the course of experimentation before embarking upon
the process of testing and data collection. A few of the considerations to keep in mind at
this stage are a thorough and precise objective identifying the need to conduct the
investigation, assessment of time and resources available to achieve the objective and
integration of prior knowledge to the experimentation procedure. A team composed of
individuals from different disciplines related to the product or process should be used to
identify possible factors to investigate and the most appropriate response(s) to measure. A
team approach promotes synergy that gives a richer set of factors to study and thus a more
complete experiment. Carefully planned experiments always lead to increased
understanding of the product or process. Well planned experiments are easy to execute and
analyze. Botched experiments, on the other hand, may result in data sets that are
inconclusive and may be impossible to analyze even when the best statistical tools are
available.

2) Screening

Screening experiments are used to identify the important factors that affect the process
under investigation out of the large pool of potential factors. These experiments are carried
out in conjunction with prior knowledge of the process to eliminate unimportant factors
and focus attention on the key factors that require further detailed analyses. Screening
experiments are usually efficient designs requiring few executions, where the focus is not
on interactions but on identifying the vital few factors.

3) Optimization

Once attention has been narrowed down to the important factors affecting the process, the
next step is to determine the best setting of these factors to achieve the desired objective.
Depending on the product or process under investigation, this objective may be to either
increase yield or decrease variability or to find settings that achieve both at the same time.

 Factorial Designs Overview describes methods for designing and analysing factorial
designs.
 Response Surface Designs Overview describes methods for designing and analyzing
central composite and Box-Behnken designs.
 Mixture Designs Overview describes methods for designing and analyzing simplex
centroid, simplex lattice, and extreme vertices designs. Mixture designs are a special

42
 class of response surface designs where the proportions of the components (factors),
rather than their magnitude, are important.
 Response Optimization describes methods for optimizing multiple responses. Minitab
provides numerical optimization, an interactive graph, and an overlaid contour plot to
help you determine the "best" settings to simultaneously optimize multiple responses.
 Taguchi Designs Overview describes methods for analyzing Taguchi designs. Taguchi
designs may also be called orthogonal array designs, robust designs, or inner-outer
array designs. These designs are used for creating products that are robust to conditions
in their expected operating environment.

4) Verification

This final stage involves validation of the best settings by conducting a few follow-up
experimental runs to confirm that the process functions as desired and all objectives are
met.

3.3.3 Methods of DOE

Following methods are used in design of experiment.

1. Factorial method
2. Response surface method
3. Taguchi method

1. Factorial method

Factorial design allows simultaneous study of effect that several factors may have on a
process. When performing an experiment, varying the level of factor simultaneously rather
than one at a time is efficient in terms of time and cost, and also allow for the study of
interaction between the factors. Interaction is the driving force in many times processes.
Without the use of factorial experiments, important interaction remains undetected.
However, factorial design can only give relative values, and to achieve actual numerical
values the math becomes difficult, as regressions (which require minimizing a sum of
values) need to be performed. Regardless, factorial design is a useful method to design
experiments in both laboratory and industrial settings.

2. Response surface method

Response surface methods are used to examine the relationship between one or more
response variables and a set of quantitative experimental variables or factors. These
methods are often employed after you have identified the important controllable factors
and you want to find the factor setting that optimizes the response.

43
3. Taguchi method

This experiment design proposed by Taguchi involves using orthogonal array to organize
the parameters affecting the process and the levels at which they should be varied; it
allows for the collection of the necessary data to determine which factor most affect
product quality with a minimum amount of experimentation, thus saving time and
resources.

3.4 Full Factorial Method

For this experiment our team chooses full factorial method. In statistics, a full factorial
experiment is an experiment whose design consists of two or more factors, each with
discrete possible values or "levels", and whose experimental units take on all possible
combinations of these levels across all such factors. A full factorial design may also be
called a fully crossed design. Such an experiment allows the investigator to study the
effect of each factor on the response variable, as well as the effects of interactions between
factors on the response variable.
For the vast majority of factorial experiments, each factor has only two levels. For
example, with two factors each taking two levels, a factorial experiment would have four
treatment combinations in total, and is usually called a 2×2 factorial design.
In full factorial method, if number of levels are same for each factors then the possible
design N=Lm.
Where, L = no. of levels for each factors
m = no. of factors

3.4.1 Steps in full factorial design

Following are steps to applying in full factorial design,

1. Identify the important statistical analysis variable.
2. Statistically analyze a data set.
3. Explain the proper steps in developing a full factorial design.
4. Design a full factorial experiment
5. Evaluate the results of experimental data.

3.4.2 Selection of process parameters

Most researchers identified plasma arc cutting process parameters that greatly affect
response parameters. Process parameters like cutting speed, arc current, gas pressure, arc
gap, kerf are most frequently used parameters for research work. Thus taking Cutting
Speed [mm/min], Current Flow Rate [amp] and Gas Pressure [kgf/cm2] for research works
and analyze for Surface Roughness (μm) and Material Removal Rate for plasma arc
cutting process.

44
As Table 3.3 shows, the level value is determined by its operation according to the
correlated processing parameter of mechanical equipment.

 Process parameters

 Factor A: Cutting Speed (mm/min)

 Factor B: Arc Current (amp)
 Factor C: Gas Pressure (kgf/cm2)

 Process parameters with levels value

Table 3.3 Process parameters with levels value

Sr.
Factors Level 1 Level 2 Level 3 Level 4 Level 5
No.

1 Cutting Speed 2850 3150 3450 3750 4050

(mm/min)
2 Arc Current (amp) 80 130 - - -
3 Gas Pressure (kgf/cm2) 80 100 120 - -

 Fixed variables

Table 3.4 Fixed variables value

Sr. No. Fixed Variables Set Value
1 Work material SAILMA
2 Sample Dimensions (100mm × 100 mm × 6 mm)

3.4.3 Experimental design

Experimental design of three process parameters with their range and levels are shown in
Table 3.5.
Table 3.5 Process parameters levels and range
Level Cutting Speed(mm/min) Arc Current (amp) Gas Pressure (kgf/cm2)
1 2850 80 80
2 2850 80 100
3 2850 80 120
4 2850 130 80
5 2850 130 100
6 2850 130 120
7 3150 80 80
8 3150 80 100
9 3150 80 120
10 3150 130 80

45
 11 3150 130 100
12 3150 130 120
13 3450 80 80
14 3450 80 100
15 3450 80 120
16 3450 130 80
17 3450 130 100
18 3450 130 120
19 3750 80 80
20 3750 80 100
21 3750 80 120
22 3750 130 80
23 3750 130 100
24 3750 130 120
25 4050 80 80
26 4050 80 100
27 4050 80 120
28 4050 130 80
29 4050 130 100
30 4050 130 120

3.5 Summary

In this chapter we have discussed about the selected process parameters, response
variables and fixed variables for the experiment. We have also discussed about the
procedure for the design of experiment, DOE table and briefly discussed about Design
expert software. In next chapter we will discuss on experimental work for machine and its
specification, material specification and also discussed about measurement of response
variables.

46
 CHAPTER 4
EXPERIMENTAL SETUP AND MESUREMENT

4.1 MACHINE DESCRIPTION USED IN INDUSTRY

1) Machine name: Messer plasma cutting machine (Fig 4.2);

2) Tool coverage: 2500 mm to 7500 mm;
3) Materials processed: steel, stainless steel or aluminum
4) Tools available: (Fig 4.1);

Beveling

Oxy fuel
nozzle

Fig 4.1 Tool of plasma cutting machine

(At. GUJARAT APOLLO EQUIPMENTS LTD., DHOLASAN)

1) Beveling
2) Oxy fuel
5) Cutting capacity:
1) 3 mm to 20 mm (For beveling Nozzle)
2) 20 mm to 200 mm (For Oxy-fuel Nozzle)
6) Fuel used:
1) Beveling Nozzle: - Plasma + Oxygen
2) Oxy-fuel nozzle: - Oxygen + LPG
7) Coolant: water 69.5%+propylene glycol 30%+other liquid 0.5%
8) Speed of range:1 to 1000 ipm
9) Control type : PC based global control plus

47
 Fig 4.2 Messer plasma cutting machine use in company
(At. GUJARAT APOLLO EQUIPMENTS LTD., DHOLASAN)

4.2 Material Selection

Material selection for this dissertation work is SAILMA. A high strength structural steel supplied
in quenched and tempered condition. The steel is designed to provide excellent welding and
bending properties and it offers substantial possibilities for savings in material costs, processing
and handling. Due to its high strength, it enables design of lighter, more durable and efficient
products and structures.

Applications:

 Machine building,
 Lifting and mobile equipment,
 Vehicles and transport equipment,
 Steel constructions,
 Framework structures,
 Construction of bridges,
 Containers Pylons and other architectural structures

48
 Table 4.1 Chemical composition of SAILMA
Elements % Contribution Elements % Contribution
Carbon 0.180 Aluminium 0.037
Manganese 1.300 Chromium 0.010
Sulfur 0.007 Nickel 0.008
Phosphorus 0.015 Boron 0.000
Silicon 0.205 Nitrogen 0.005
Cuprum 0.010 Vanadium 0.057

 The test report is attached in Appendix 1.

 The mechanical properties and melting range of SAILMA has shown in Table 4.2.

Table 4.2 Properties of SAILMA

Properties Range
Ultimate tensile strength (MPa) 552
Yield strength (MPa) 420
Elongation % 20

4.3 Surface Roughness Measurement

Surface roughness values of finished work pieces were measured by Mitutoyo Surface
Roughness Tester SJ – 201 by a proper procedure. The Mitutoyo Surface Roughness Tester SJ –
201 is an instrument that works by gently dragging a mechanical stylus across a Surface. Surface
Roughness Tester acquires data by moving the sample beneath the diamond tipped stylus.
Vertical movements of the stylus are sensed by an LVDT, digitalized, and stored in the
instruments memory. Its output is a digital display of measured Surface roughness value Ra and
other features. Surface Roughness Standard ISO was used for measurement. The temperature of
environment was 32 ± 1◦C. In this present study we have taken Ra for measuring Surface
Roughness.

49
4.3.1 Technical specification of surface roughness tester
Table 4.3 Technical specification of Mitutoyo surface roughness tester SJ-201
1. Detector:
Detection Method Different Inductance Method

350µm (-200 µm to + 150 µm)

Measurement range
1370 µin (-7880 µin to + 5900 µin)

Stylus material Diamond

5 µm (200 µin)
Tip radius
2 µm (80 µin) (0.75 MN measuring force type)

4 MN (0.4 gf)
Measuring force 0.75 MN (0,075 gf) (0.75 MN measuring force
type)
Radius of skid curvature 40 mm (1.57 in)

2. Drive Unit:
Drive Unit
Detector drive range 21 mm (0.82 in)

Traversing speed Measurement 0.25 mm/s, 0.5 mm/s (0.10 in/s, 0.02 in/s)
Return 0.8 mm/s (0.30 in/s)

Detector retraction function Stylus UP

Bottom configure ration V – way
Ra Ra (0.01 µm to 100 µm )

50
 Fig. 4.3 Mitutoyo surface roughness tester SJ-201

4.4 Material Removal Rate Measurement

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 [gms/sec]

Where, WRW: work piece removal weight (gms)

T: cutting time (sec)

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 (gms/ mm3)

MRR calculation sheet is shown in Table 4.5.

51
 Table 4.4 MRR calculation sheet
∆m=m- Time
SPECIMEN mL mR m MRR=∆m/t
Sr. No. (mL+mR) (t)
NO. (gms) (gms) (gms) (gms/sec)
(gms) (sec)
1 17 284.1 316.1 608.9 8.7 2.67 3.25840
2 30 311.5 281.2 601.5 8.8 2.41 3.65150
3 26 312.7 283.4 604.8 8.7 2.52 3.45240
4 5 279.8 324.6 617.1 12.7 2.52 5.03970
5 1 278.9 320.1 613.9 14.9 2.70 5.52150
6 3 302.5 295.5 611.4 13.4 2.57 5.22000
7 24 264.3 342.1 614.7 8.3 2.41 3.44400
8 25 297.2 301.4 606.7 8.1 2.37 3.41770
9 28 263.9 330.8 602.8 8.1 2.51 3.22710
10 13 273.3 327.5 613.3 12.5 2.50 5.00000
11 9 308.6 289.3 609.5 11.6 2.30 5.04536
12 21 307.1 291.5 610.8 12.2 2.38 5.12610
13 23 290.2 307.8 605.5 7.5 2.08 3.60580
14 29 264.1 341.2 612.9 7.6 2.08 3.65380
15 27 279.3 330.7 617.3 7.3 2.45 2.97960
16 10 276.2 324.3 612.1 11.6 2.34 4.95730
17 8 300.6 287.2 598.4 10.6 2.12 4.99400
18 19 280.6 320.3 612.4 11.5 2.30 4.97900
19 22 277.8 327.9 610.6 4.9 2.03 2.41380
20 6 284.4 319.7 609.5 5.4 2.07 2.60870
21 15 290.4 324.7 621.3 6.2 2.45 2.53216
22 11 290.0 311.6 612.7 11.1 2.27 4.88990
23 7 263.6 337.2 612.6 11.8 2.35 5.02130
24 18 272.4 322.8 606.4 11.2 2.23 5.02240
25 20 325.7 282.0 612.0 4.3 2.17 1.98160
26 12 343.3 270.4 618.8 5.1 2.31 2.21825

52
 27 14 313.0 291.7 610.0 5.3 2.45 2.16330
28 2 287.0 312.5 610.2 10.7 2.29 4.67250
29 4 296.4 312.7 619.0 9.9 2.19 4.52050
30 16 275.9 328.0 614.3 10.4 2.37 4.38567

4.5 Experimental Result

From the measurements of surface roughness and material removal rate obtain results are shown
in Table 4.5.

Table 4.5 Result of surface roughness and material removal rate obtain from experimental
work
Process Parameters Response Variables
Exp. Cutting Arc Gas
No. Speed Current Pressure Surface Material Removal
(mm/min) (amp) (kgf/cm2) Roughness (µm) rate (gms/sec)

1 2850 80 80 0.570 3.25840

2 2850 80 100 0.630 3.65150

3 2850 80 120 0.950 3.45240

4 2850 130 80 0.500 5.03970

5 2850 130 100 0.830 5.52150

6 2850 130 120 1.100 5.22000

7 3150 80 80 0.385 3.44400

8 3150 80 100 0.580 3.41770

9 3150 80 120 0.750 3.22710

10 3150 130 80 0.215 5.00000

11 3150 130 100 0.450 5.04536

12 3150 130 120 0.700 5.12610

13 3450 80 80 0.520 3.60580

53
 14 3450 80 100 0.680 3.65380

15 3450 80 120 0.830 2.97960

16 3450 130 80 0.260 4.95730

17 3450 130 100 0.685 4.99400

18 3450 130 120 0.910 4.97900

19 3750 80 80 0.650 2.41380

20 3750 80 100 0.910 2.60870

21 3750 80 120 1.040 2.53216

22 3750 130 80 0.370 4.88990

23 3750 130 100 0.710 5.02130

24 3750 130 120 0.870 5.02240

25 4050 80 80 0.560 1.98160

26 4050 80 100 0.670 2.21825

27 4050 80 120 0.930 2.16330

28 4050 130 80 0.420 4.67250

29 4050 130 100 0.860 4.52050

30 4050 130 120 1.100 4.38567

4.6 Summary

In this chapter we have discussed about machine specification, material selection, how to
measure and find the values of surface roughness and material removal rate in plasma arc cutting
process. The measured values of response parameters as per the DOE are listed in the result
table. In next chapter we will discuss on analysis of variance for find out percentage contribution
of process parameters on response variables.

54
 CHAPTER 5
ANOVA ANALYSIS

5.1 ANALYSIS OF VARIANCE

5.1.1 Introduction
The analysis of variance (ANOVA) is the statistical treatment most commonly applied to the
results of the experiments to determine the percentage contribution of each factors. Study of
ANOVA table for a given analysis helps to determine which of the factors need control and
which do not. Once the optimum condition is determined, it is usually good practice to run a
confirmation experiments. In case of fractional factorial some of the tests of full factorial are
conducted. The analysis of the partial experiment must include an analysis of confidence that can
be placed in the results. So analysis of variance is used to provide a measure of confidence.

Analysis provides the variance of controllable and noise factors. By understanding the source
and magnitude of variance, robust operating condition can be predicted.

5.1.2 Analysis of variance (ANOVA) Terms & Notations

n = Number of trials C.F. = Correction factor

E = Error P = Percentage contribution

F = Variance ratio T = Total of results

𝑓 = Degree of freedom S = sum of squares

𝑓E = Degree of freedom of error V = Mean squares (variance)

𝑓T = total degree of freedom

Total number of trials

The total number of trial is the sum of numbers of trials at each level.

Degree of freedom

It is a measure of amount of information that can be uniquely determined from a given set of
data. DOF for data concerning a factor equals one less than the number of levels.

Sum of squares

The sum of squares is the measure of the deviation of the experimental data from the mean value
of the data.

55
Variance

Variance measures the distribution of the data about the mean of the data.

Variance ratio

Variance ratio is the ratio of variance due to the effect of a factor and variance due to the error
term. This ratio is used to measure the significance of the factor under investigation with respect
to the variance of all the factors included in the error term. The F value obtained in the analysis is
compared with a value from standard F – tables for a given level of significance. When the
computed value is less than the value determined from the F tables at the selected level of
significance, the factor does not contribute to the sum of squares within the confidence level.

Table 5.1 Process parameters with level values

Sr. No. Factors Level 1 Level 2 Level 3 Level 4 Level 5

1 Cutting Speed (mm/min) 2850 3150 3450 3750 4050

2 Arc Current (amp) 80 130 - - -
3 Gas Pressure (kgf/cm2) 80 100 120 - -

Table 5.2 Table 5.2 Range of process parameters and response variables

Process Parameters Response Variables

Exp. Cutting Arc Gas
No. Speed Current Pressure Surface Material Removal
(mm/min) (amp) (kgf/cm2) Roughness (µm) rate (gms/sec)

1 2850 80 80 0.570 3.25840

2 2850 80 100 0.630 3.65150

3 2850 80 120 0.950 3.45240

4 2850 130 80 0.500 5.03970

5 2850 130 100 0.830 5.52150

6 2850 130 120 1.100 5.22000

7 3150 80 80 0.385 3.44400

8 3150 80 100 0.580 3.41770

56
9 3150 80 120 0.750 3.22710

10 3150 130 80 0.215 5.00000

11 3150 130 100 0.450 5.04536

12 3150 130 120 0.700 5.12610

13 3450 80 80 0.520 3.60580

14 3450 80 100 0.680 3.65380

15 3450 80 120 0.830 2.97960

16 3450 130 80 0.260 4.95730

17 3450 130 100 0.685 4.99400

18 3450 130 120 0.910 4.97900

19 3750 80 80 0.650 2.41380

20 3750 80 100 0.910 2.60870

21 3750 80 120 1.040 2.53216

22 3750 130 80 0.370 4.88990

23 3750 130 100 0.710 5.02130

24 3750 130 120 0.870 5.02240

25 4050 80 80 0.560 1.98160

26 4050 80 100 0.670 2.21825

27 4050 80 120 0.930 2.16330

28 4050 130 80 0.420 4.67250

29 4050 130 100 0.860 4.52050

30 4050 130 120 1.100 4.38567

57
5.2 Analysis of Variance for Surface Roughness
Total no of runs (n) = 30
Total degree of freedom 𝑓T = n - 1 = 29

Three factors and their levels:

Cutting Speed A: A1, A2, A3, A4, A5

Arc Current B: B1, B2

Gas Pressure C: C1, C2, C3

Degree of freedom:

Factor A – Number of level of factor A - 1 = 𝑓A = 4

Factor B – Number of level of factor B - 1 = 𝑓B = 1

Factor C – Number of level of factor C - 1 = 𝑓C = 2

For error 𝑓E = 𝑓T – 𝑓A – 𝑓B – 𝑓C = 29 – 4 – 1 – 2 = 𝑓E = 22

T = Total of all SR value results = 20.635

Correction factor C.F. = (T2 / n) = (20.6352 / 30) = 14.1934

Total sum of squares:

ST = ∑ - C.F. = 15.8292 – 14.1934 = 1.6358

The total contribution of each factor level:

A1 = 0.570 + 0.630 + 0.950 + 0.500 + 0.830 + 1.100

= 4.58

A2 = 0.385 + 0.580 + 0.750 + 0.215 + 0.450 + 0.700

= 3.08

A3 = 0.520 + 0.680 + 0.830 + 0.260 + 0.685 + 0.910

= 3.885

A4 = 0.650 + 0.910 + 1.040 + 0.370 + 0.710 + 0.870

= 4.55

A5 = 0.560 + 0.670 + 0.930 + 0.420 + 0.860 + 1.100

58
 = 4.54

B1 = 0.570 + 0.630 + 0.950 + 0.385 + 0.580 + 0.750 + 0.520 + 0.680 + 0.830 + 0.650 + 0.910 +
1.040 + 0.560 + 0.670 + 0.930

= 10.655

B2 = 0.500 + 0.830 + 1.100 + 0.215 + 0.450 + 0.700 + 0.260 + 0.685 + 0.910 + 0.370 + 0.710 +
0.870 + 0.420 + 0.860 + 1.100

= 9.98

C1 = 0.570 + 0.500 + 0.385 + 0.215 + 0.520 + 0.260 + 0.650 + 0.370 + 0.560 + 0.420

= 4.45

C2 = 0.630 + 0.830 + 0.580 + 0.450 + 0.680 + 0.685 + 0.910 + 0.710 + 0.670 + 0.860

= 7.005

C3 = 0.950 + 1.100 + 0.750 + 0.700 + 0.830 + 0.910 + 1.040 + 0.870 + 0.930 + 1.100

= 9.18

Factor sum of squares:

SA = /NA1 + /NA2 + /NA3 + /NA4 + /NA5 – C.F.

= (4.58)2/6 + (3.08)2/6 + (3.885)2/6 + (4.55)2/6 + (4.54)2/6 – 14.1934

= 0.2850

SB = /NB1 + /NB2 – C.F.

= (10.655)2/15 + (9.98)2/15 – 14.1934

= 0.0152

SC = /NC1 + /NC2 + /NC3 – C.F.

= (4.45)2/10 + (7.005)2/10 + (9.18)2/10 – 14.1934

= 1.1211

SE = ST – (SA + SB + SC)

= 1.6358 – (0.2850 + 0.0152 + 1.1211 )

= 0.2145

59
Mean square (variance):

VA = SA / 𝑓 A = 0.2850 / 4 = 0.07125

VB = SB / 𝑓B = 0.0152 / 1 = 0.0152

VC = SC / 𝑓C = 1.1211 / 2 = 0.56055

VE = SE / 𝑓 E = 0.2145 / 22 = 0.00975

Variance ratio F:

FA = VA / VE = 0.07125 / 0.00975 = 7.3077

FB = VB / VE = 0.0152 / 0.00975 = 1.5590

FC = VC / VE = 0.56055 / 0.00975 = 57.4923

FE = VE / E = 0.00975 / 0.00975 = 1

Percentage contribution:

PA = SA / ST = 0.2850 / 1.6358 = 17.42

PB = SB / ST = 0.0152 / 1.6358 = 0.92

PC = SC / ST = 1.1211 / 1.6358 = 63.54

PE = SE / ST = 0.2145 / 1.6358 = 13.11

Table 5.3 shows the summary of analysis of variance for surface roughness.

Table 5.3 Summary of ANOVA calculation for SR

Variance
Sum of Variance Percentage
Source of variation 𝑓 (Mean
squares ratio F contribution
square)
Factor-A,
4 0.2850 0.07125 7.3077 17.42
Cutting Speed
Factor-B,
1 0.0152 0.0152 1.5590 0.92
Arc Current
Factor-C,
2 1.1211 0.56055 57.4923 63.54
Gas Pressure
Error – E 22 0.2145 0.00975 1 13.11

Total 29 1.6358

60
Following is the MINITAB 16 window in which ANOVA results for Surface Roughness is
shown, which is mostly nearer to the calculated value.

5.3 Analysis of Variance for Material Removal Rate

Total no of runs (n) = 30

Total degree of freedom 𝑓T = n - 1 = 29

Three factors and their levels:

Cutting Speed A: A1, A2, A3, A4, A5

Arc Current B: B1, B2

Gas Pressure C: C1, C2, C3

Degree of freedom:

Factor A – Number of level of factor A - 1 = 𝑓A = 4

Factor B – Number of level of factor B - 1 = 𝑓B = 1

Factor C – Number of level of factor C - 1 = 𝑓C = 2

For error 𝑓E = 𝑓T – 𝑓A – 𝑓B – 𝑓C = 29 – 4 – 1 – 2 = 𝑓E = 22

61
T = Total of all depth value results = 119.00334

Correction factor C.F. = (T2 / n) = (119.003342 / 30) = 472.05983

Total sum of squares:

ST = ∑ - C.F. = 507.6487 – 472.05983 = 35.58887

The total contribution of each factor level:

A1 = 3.25840 + 3.65150 + 3.45240 + 5.03970 + 5.52150 + 5.22000

= 26.1435

A2 = 3.44400 + 3.41770 + 3.22710 + 5.00000 + 5.04536 + 5.12610

= 25.2603

A3 = 3.60580 + 3.65380 + 2.97960 + 4.95730 + 4.99400 + 4.97900

= 25.1695

A4 = 2.41380 + 2.60870 + 2.53216 + 4.88990 + 5.02130 + 5.02240

= 22.4883

A5 = 1.98160 + 2.21825 + 2.16330 + 4.67250 + 4.52050 + 4.38567

= 19.9418

B1 = 3.25840 + 3.65150 + 3.45240 + 3.44400 + 3.41770 + 3.22710 + 3.60580 + 3.65380 +

2.97960 + 2.41380 + 2.60870 + 2.53216 + 1.98160 + 2.21825 + 2.16330

= 44.6081

B2 = 5.03970 + 5.52150 + 5.22000 + 5.00000 + 5.04536 + 5.12610 + 4.95730 + 4.99400 +

4.97900 + 4.88990 + 5.02130 + 5.02240 + 4.67250 + 4.52050 + 4.38567

= 74.3952

C1 = 3.25840 + 5.03970 + 3.44400 + 5.00000 + 3.60580 + 4.95730 + 2.41380 + 4.88990 +

1.98160 + 4.67250

= 39.263

C2 = 3.65150 + 5.52150 + 3.41770 + 5.04536 + 3.65380 + 4.99400 + 2.60870 + 5.02130 +

2.21825 + 4.52050

= 40.6526

62
C3 = 3.45240 + 5.22000 + 3.22710 + 5.12610 + 2.97960 + 4.97900 + 2.53216 + 5.02240 +
2.16330 + 4.38567

= 39.0877

Factor sum of squares:

SA = /NA1 + /NA2 + /NA3 + /NA4 + /NA5 – C.F.

= (26.1435)2/6 + (25.2603)2/6 + (25.1695)2/6 + (22.4883)2/6 + (19.9418)2/6 – 472.05983

= 4.3515

SB = /NB1 + /NB2 – C.F.

= (44.6081)2/15 + (74.3952)2/15 – 472.05983

= 29.5754

SC = /NC1 + /NC2 + /NC3 – C.F.

= (39.263)2/10 + (40.6526)2/10 + (39.0877)2/10 – 472.05983

= 0.1467

SE = ST – (SA + SB + SC)

= 35.58887 – (4.3515 + 29.5754 + 0.1467)

= 1.51527

Mean square (variance):

VA = SA / 𝑓 A = 4.3515 / 4 = 1.08788

VB = SB / 𝑓B = 29.5754 / 1 = 29.5754

VC = SC / 𝑓C = 0.1467 / 2 = 0.07335

VE = SE / 𝑓 E = 1.51527 / 22 = 0.06888

Variance ratio F:

FA = VA / VE = 1.08788 / 0.06888 = 15.7938

FB = VB / VE = 29.5754 / 0.06888 = 429.3757

FC = VC / VE = 0.07335 / 0.06888 = 1.0649

63
FE = VE / E = 0.06888 / 0.06888 = 1

Percentage contribution:

PA = SA / ST = 4.3515 / 35.58887 = 12.23

PB = SB / ST = 29.5754 / 35.58887 = 83.10

PC = SC / ST = 0.1467 / 35.58887 = 0.41

PE = SE / ST = 1.51527 / 35.58887 = 4.26

Table 5.5 shows the summary of analysis of variance for depth.

Table 5.4 Summary of ANOVA calculation for MRR

Variance
Sum of Variance Percentage
Source of variation 𝑓 (Mean
squares ratio F contribution
square)
Factor-A,
4 4.3515 1.08788 15.7938 12.23
Cutting Speed
Factor-B,
1 29.5754 29.5754 429.3757 83.10
Arc Current
Factor-C,
2 0.1467 0.07335 1.0649 0.41
Gas Pressure

Error – E 22 1.51527 0.06888 1 4.26

Total 29 35.58887

64
Following is the MINITAB 16 window in which ANOVA results for MRR is shown, which is
mostly nearer to the calculated value.

5.4 Result Discussion

From the above ANOVA analysis we can conclude that, 1) for surface roughness percentage
contribution of cutting speed 17.42 %, arc current 0.92 %, gas pressure 63.54 %, error 13.11 %,
2) for material removal rate percentage contribution of cutting speed 12.23 %, arc current 83.10
%, gas pressure 0.41 %, and error 4.26 %. This error is due to machine vibration.

5.5 Summary

In this chapter we have discussed about the introduction of ANOVA and mathematical step for
find out the percentage contribution of each process parameters on response variables. In next
chapter we will discuss on grey relational analysis for our process.

65
 CHAPTER 6
MULTI RESPONSE OPTIMIZATION

6.1 Grey Relational Analysis for Multi Objective Optimization

The grey relational analysis (GRA) is one of the powerful and effective soft-tool to analyze
various processes having multiple performance characteristics Grey relational Analysis (GRA)
Technique is used to solve the problems of the systems that are complex and multivariate.
Generally, GRA is carried out for solving complicated problems which have interrelationships
among the designated performance characteristics. The purpose of grey relational analysis the
multi-objective problem has been converted into single objective optimization using GRA
technique. GRA is alternate method for traditional statistical methods which deals with the small
sample size and uncertainty conditions and can be applied in optimization of multiple quality
characteristics. GRA is normalization based evolution technique in which the quality
characteristics of the measured data are first normalized ranging from 0 to 1. Therefore one has
to pre-process the data which are related to a group of sequence ,which is called “grey relational
generation “data preprocessing is a process of transferring the original sequence to a comparable
sequence for this purpose the experimental result are normalized in the range between zero and
one.

Table 6.1 Quality characteristics of the machining performance

Sr. No. Machine Characteristic Quality Characteristic
1 SR (Surface Roughness) Minimum
2 MRR (Material Removal Rate) Maximum

6.1.1 Data pre-processing

Normalize the measured values of Surface roughness and Material removal rate ranging from
zero to one. This process is known as Grey relational normalization.

If the target value of original sequence is infinite, then it has a characteristic of “the larger the
better” than the original sequence can be normalized as follows:

yi ( k )min yi ( k )
xi ( k )  max yi ( k )  min yi ( k )
……………… (6.1)

If the expectancy is “the smaller the better” than the original sequence should be normalized as
follows:

maxyi ( k ) yi ( k )
xi ( k )  max yi ( k )  min yi ( k ) …………….. (6.2)

66
Here X (k) i is the value after grey relational generation, min y(k)i is the smallest value of y (k) i
for the kth response, and max y (k) i is the largest value of y (k) i for the kth response. An ideal
sequence is (1, 2, 3..., 30) 0 x k, k = for the responses. The definition of grey relational grade in
the course of grey relational analysis is to reveal the degree of relation between the 30 sequences,
(1, 2, 3..., 30) 0 x k and x k, k = i.

6.1.2 Grey relational coefficient and grey relational grade

Following data pre-processing, a grey relational coefficient is calculated to express the

relationship between the ideal and actual normalized experimental results. The Grey relation
coefficient can be express as follows:
Δmin + ψΔmax
ζi(k) =
Δ 0i(k) + ψΔmax ……………….. (6.3)
Where  0i (k ) is the deviation sequence of the reference sequence xi(k ) and the comparability
sequence.ᴪ = distinguishing or identification coefficient in between zero and one. GRC is
calculated by selecting proper distinguishing coefficient generally ᴪ = 0.5 is accepted .In the
present study same was considered.

Δ 0i = x 0 (k)- x i (k) ………………... (6.4)

Δmin = min min x 0 (k)- x i (k)

i I k ………………. (6.5)

Δmax = max max x 0

(k) - x i(k) ………….. (6.6)
iI k

 is distinguishing or identification coefficient:   [0,1], is generally used.

After obtaining the Grey relation coefficient, its average is calculated to obtain the Grey relation
grade.
The Grey relation grade is defined as follows:
n
1
γi =
n
 ζi(k)
k =1 ……………… (6.7)
Where n is the no of process responses, ζi is the grey rational grade for the kth experiment.
The GRG is used to analyze the relational degree of multiple response characteristics. Higher the
grey relational grade represent a stronger relational degree between the ideal normalized value
xok and the given sequences xik.
In Grey relation analysis, the grey relation grade is used to show the relationship among the
sequences. The Grey relation grade also indicates the degree of influence that the comparability

67
sequence could exert over the reference sequence. Therefore, if a particular comparability
sequence is more important than the other comparability sequence to reference sequence will be
higher than other grey relation grades. In this study, the importance of both the comparability
sequence and reference sequence is treated as equal.

6.2 PROCESS STEPS FOR MULTI RESPONSE OPTIMIZATION

The basic process steps for multi-response optimization are given below:
a). Normalization of experimental results for all performance characteristics.
b). Calculation of grey relational coefficient (GRC).
c). Calculation of grey relational grade (GRG) using weighing factor for performance
characteristics.
d). Analysis of experimental results using GRG.
e). Selection of optimal levels of process parameters.
f). Conducting confirmation experiment to verify optimal process parameter settings.

6.3 NORMALIZATION OF EXPERIMENTAL RESULTS

In this research work, normalization of surface roughness and material removal rate is done
between 0 and 1. Here for surface roughness and material removal rate, normalization equation
smaller-the-better, larger-the-better is used is shown in Table 6.2.

Table 6.2 Data Pre-Normalization

Exp. No. Data Pre-Normalization
SR MRR
1 0.5989 0.3607

2 0.5311 0.4717

3 0.1695 0.4155

4 0.6780 0.8639

5 0.3051 1.0000

6 0.0000 0.9148

7 0.8079 0.4131

8 0.5876 0.4057

9 0.3955 0.3518

68
10 1.0000 0.8527

11 0.7345 0.8655

12 0.4520 0.8883

13 0.6554 0.4588

14 0.4746 0.4724

15 0.3051 0.2819

16 0.9492 0.8406

17 0.4689 0.8510

18 0.2147 0.8467

19 0.5085 0.1221

20 0.2147 0.1772

21 0.0678 0.1555

22 0.8249 0.8216

23 0.4407 0.8587

24 0.2599 0.8590

25 0.6102 0.0000

26 0.4859 0.0669

27 0.1921 0.0513

28 0.7684 0.7602

29 0.2712 0.7172

30 0.0000 0.6791

69
6.4 CALCULATION OF DEVIATION SEQUENCE

In this work, to find out grey relation coefficient, one has to calculate deviation sequence using
equation (7.4) shown in table 6.3. The deviation sequences ∆0i, ∆max (k), and ∆min (k) for i=1-
30 and k=1-2can be calculated as follows:
∆01 (1) =|x0 (1) – x1 (1)| = |1.0000 – 0.5989| = 0.4011
∆01 (2) =|x0 (2) – x1 (2)| = |1.0000 – 0.5311| = 0.4689
∆01 (3) =|x0 (3) – x1 (3)| = |1.0000 – 0.1695| = 0.8305

Table 6.3 Deviation sequences

Exp. No. Deviation Sequence
∆0i (1) ∆0i (2)
1 0.4011 0.6393

2 0.4689 0.5283

3 0.8305 0.5845

4 0.3220 0.1361

5 0.6949 0.0000

6 1.0000 0.0852

7 0.1921 0.5869

8 0.4124 0.5943

9 0.6045 0.6482

10 0.0000 0.1473

11 0.2655 0.1345

12 0.5480 0.1117

13 0.3446 0.5412

14 0.5254 0.5276

15 0.6949 0.7181

16 0.0508 0.1594

17 0.5311 0.1490

70
 18 0.7853 0.1533

19 0.4915 0.8779

20 0.7853 0.8228

21 0.9322 0.8445

22 0.1751 0.1784

23 0.5593 0.1413

24 0.7401 0.1410

25 0.3898 1.0000

26 0.5141 0.9331

27 0.8079 0.9487

28 0.2316 0.2398

29 0.7288 0.2828

30 1.0000 0.3209

Using Table 6.3, ∆max and ∆min can be found as follows:

∆max = ∆06 (1) = ∆30 (1) = ∆25 (2) = 1.0000
∆min = ∆10 (1) = ∆5 (2) = 0.0000

6.5 CALCULATION OF GREY RELATIONAL COEFFICIENT AND

GREY RELATIONAL GRADE

The grey relational coefficient is use to express the relationship between the ideal (best) and
actual normalized experimental results. Table 6.4 list the grey relational coefficient and grey
relational grade for each experiment by applying Eqe.6.3, 6.7.

71
 Table 6.4 Calculation of Grey relational Coefficient & Grey relational grade
Grey Relation Coefficients Grey Relational
Exp No: Orders
SR MRR Grade

1 0.5549 0.4389 0.4969 19

2 0.5160 0.4862 0.5011 18

3 0.3758 0.4610 0.4184 26

4 0.6083 0.7860 0.6972 6

5 0.4184 1.0000 0.7092 5

6 0.3333 0.8544 0.5939 11

7 0.7224 0.4600 0.5912 13

8 0.5480 0.4569 0.5025 17

9 0.4527 0.4355 0.4441 23

10 1.0000 0.7724 0.8862 1

11 0.6532 0.7880 0.7206 4

12 0.4771 0.8174 0.6473 8

13 0.5920 0.4802 0.5361 15

14 0.4876 0.4866 0.4871 20

15 0.4184 0.4105 0.4145 27

16 0.9078 0.7583 0.8331 2

17 0.4849 0.7704 0.6277 9

18 0.3890 0.7653 0.5772 14

19 0.5043 0.3629 0.4336 24

20 0.3890 0.3780 0.3835 28

21 0.3491 0.3719 0.3605 30

22 0.7406 0.7370 0.7388 3

72
 23 0.4720 0.7797 0.6259 10

24 0.4032 0.7800 0.5916 12

25 0.5619 0.3333 0.4476 22

26 0.4930 0.3489 0.4210 25

27 0.3823 0.3451 0.3637 29

28 0.6834 0.6759 0.6797 7

29 0.4069 0.6387 0.5228 16

30 0.3333 0.6091 0.4712 21

In grey relational analysis total performance of multi objective optimization is depending on

value of grey relational grade. According to performed experiment design, it is clearly observed
from Table 6.4 that the „plasma arc cutting process parameters‟ setting of experiment no. 10 has
the highest grey relation grade. Thus, the 10th experiment gives the best multi-performance
characteristics among the 30 experiments.

To find out the optimum level of plasma arc cutting process parameters, calculate the average
grey relational grade for each factor level. For example, the grey relational grades for factors A,
B and C at level 1 can be calculated as follows:

A1 = (0.4969 + 0.5011 + 0.4184 + 0.6972 + 0.7092 + 0.5939)

= 0.5695

B1 = (0.4969 + 0.5011 + 0.4184 + 0.5912 + 0.5025 + 0.4441 + 0.5361 + 0.4871 + 0.4145 +

0.4336 + 0.3835 + 0.3605 + 0.4476 + 0.4210 + 0.3637)

= 0.4535

C1 = (0.4969 + 0.6972 + 0.5912 + 0.8862 + 0.5361 + 0.8331 + 0.4336 + 0.7388 + 0.4476 +

0.6797)

= 0.6340

The same way we calculate for factors A, B, C at level 2 and level 3. Result are shown in Table
6.5

73
 Table 6.5 Response table for grey relational grade
Average grey relational grade by factor level
Machining parameters
Level 1 Level 2 Level 3 Level 4 Level 5

0.5695 0.6320* 0.5793 0.5223 0.4843

Cutting Speed (mm/min)

Arc Current (amp) 0.4535 0.6615* - - -

Gas Pressure (kgf/cm2) 0.6340* 0.5501 0.4882 - -

Table 6.5 shows average grey relational grade by factor level. From this table, one has concluded
optimum parameter levels which are indicated by “*”. In this table, higher grey relational grade
from each level of factor indicates the optimum level. From this table it is concluded that the
optimum parameter level for Cutting Speed, Arc Current, Gas Pressure is (3150 mm/min), (130
amp) and (80 kgf/cm2) respectively.

6.6 ANALYSIS AND DISCUSSION OF EXPERIMENTAL RESULTS

Optimal parameter combination on the SAILMA 100mm × 100mm × 8mm work-piece for
surface roughness and material removal rate with different combinations of plasma arc cutting
process parameter of 30 experimental runs.

6.6.1 Graph for grey relational grades

1
0.9
Gray Relational Grade

0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Experimental Runs

Fig 6.1 Graph for Grey relational grades

74
According to performed experimental design, it is clearly observed from Table 6.4 and the Grey
relational grade graph (Figure 6.1) which shows the change in the response when the factors go
from one level to other that the laser engraving process parameters setting of experiment no. 10
has highest grey relation grade. Thus, the 10th experiment gives the best multi- performance
characteristics of the plasma arc cutting process among the 30 experiments.

6.6.2 Main effect plot for grey relational grade

Main Effects Plot for Gray Relational Grade

Data Means
0.650

0.625

0.600

0.575
Mean

0.550

0.525

0.500

2850 3150 3450 3750 4050

Cutting Speed (mm/min)

Fig 6.2 Graph of grey relational grade v/s Cutting Speed (mm/min)

Figure 6.2 shows the effect of cutting speed on grey relational grade. From this graph we
conclude that at 3150 mm/min cutting speed, grey relational grade is higher compare to 2850
mm/min, 3450 mm/min, 3750 mm/min and 4050 mm/min cutting speed. So, 3150 mm/min is
optimum parameter level from five level of cutting speed.

Figure 6.3 shows the effect of Arc Current on grey relational grade. From this graph we conclude
that at 130 amp arc current, grey relational grade is higher compare to 80 amp arc current. So,
130 amp is optimum parameter level from two level of arc current.

75
 Main Effects Plot for Gray Relational Grade
Data Means

0.65

0.60
Mean

0.55

0.50

0.45
80 130
Arc Current (amp)

Fig 6.3 Graph of grey relational grade v/s Arc Current (amp)

Main Effects Plot for Gray Relational Grade

Data Means
0.650

0.625

0.600

0.575
Mean

0.550

0.525

0.500

80 100 120
Gas Pressure (kgf/cm2)

Fig 6.4 Graph of grey relational grade v/s Gas Pressure (kgf/cm2)

76
Figure 6.4 shows the effect of gas pressure on grey relational grade. From this graph we
conclude that at 80 kgf/cm2 gas pressure, grey relational grade is higher compare to 100 kgf/cm2
and 120 kgf/cm2 gas pressure. So, 80 kgf/cm2 is optimum parameter level from three level of gas
pressure.

6.7 Confirmation Test

The final step in the experiment is to do confirmation test. The purpose of the confirmation runs
is to validate the conclusion drawn during the analysis phases. In addition, the confirmation tests
needs to be carried out in order to ensure that the theoretical predicted parameter combination for
optimum results is acceptable or not. The parameters used in the confirmation test are suggested
by grey relational analysis. The confirmation test with optimal process parameters if performed
for plasma arc cutting process of SAILMA material plate at levels A2 (3150 mm/min, cutting
speed), B2 (130 amp, arc current), C1 (80 kgf/cm2, gas pressure) and it gives surface roughness
of 0.21µm and material removal rate of 4.8590gms/sec with the error in surface roughness is
2.33 % and error in material removal rate is 2.82 %.

6.8 Summary

In this chapter we have discussed about the basics of grey relational analysis and procedure for
implementation of grey relational analysis for our experimental work. In next chapter we will
discuss about the results obtained by experimentation and grey relational analysis.

77
 CHAPTER 7
RESULT AND DISCUSSION

In previous chapter we have discussed about grey relational technique, and we have done
normalization of experimental results and then calculate deviation sequence to find out
grey relational coefficient and grey relational grade. After performing the experiment for
all 30 runs and measuring response variables like surface roughness, material removal rate
for plasma arc cutting of SAILMA, whatever results generated are discussed in this
chapter.

7.1 Main Effect Plot for Process Parameters v/s Response Variables
In this topic it covered main effect plot for surface roughness, material removal rate and
grey relational grade. These three main effect plots are combined with three process
parameters cutting speed, arc current, and gas pressure.

Main Effects Plot for Surface Roughness (µm)

Data Means
Cutting Speed (mm/min) Arc Current (amp)
0.9
0.8
0.7
Surface Roughness (µm)

0.6
0.5

2850 3150 3450 3750 4050 80 130

Gas Pressure (kgf/cm2)
0.9
0.8
0.7
0.6
0.5

80 100 120

Fig. 7.1 Graph of main effect plot for surface roughness

Figure 7.1 shows the main effect plot for surface roughness. From figure 7.1 it is clearly
shown that from 2850 mm/min to 3150 mm/min cutting speed, surface roughness is
decrease and from 3150 mm/min to 4050 mm/min cutting speed, surface roughness is
increase. So it concludes that for achieve good surface quality, cutting speed must be
required less.

Now concentrate on effect of arc current on surface roughness. From figure 7.1 it is clearly
shown that with increase in arc current, surface roughness is decrease. So it concludes that
for achieve good surface quality, arc current required must be more.

78
Now concentrate on effect of gas pressure on surface roughness. From figure 7.1 it is
clearly shown that with increase in gas pressure, surface roughness is increase. So it
concludes that for achieve good surface quality, gas pressure must be required less.

Main Effects Plot for MRR (gms/sec)

Data Means

Cutting Speed (mm/min) Arc Current (amp)

5.0

4.5

4.0

3.5
MRR (gms/sec)

3.0
2850 3150 3450 3750 4050 80 130
Gas Pressure (kgf/cm2)
5.0

4.5

4.0

3.5

3.0
80 100 120

Fig. 7.2 Graph of main effect plot for material removal rate

Figure 7.2 shows the main effect plot for material removal rate. From figure 7.2 it is
clearly shown that with increase in cutting speed, material removal rate is decrease. So it
concludes that for achieve good material removal rate, cutting speed must be required less.

Now concentrate on effect of arc current on material removal rate. From figure 7.2 it is
clearly shown that with increase in arc current, material removal rate is increase. So it
concludes that for achieve good material removal rate, arc current must be required more.

Now talk about effect of gas pressure on material removal rate. From figure 7.2 it is
clearly shown that from 80 kgf/cm2 to 100 kgf/cm2 gas pressure, material removal rate is
increase and from 100 kgf/cm2 to 120 kgf/cm2 gas pressure, material removal rate is
decrease. So it concludes that for achieve good material removal rate, gas pressure must be
required less.

79
 Main Effects Plot for Gray Relational Grade
Data Means
Cutting Speed (mm/min) Arc Current (amp)
0.65

0.60

0.55
Gray Relational Grade

0.50

0.45
2850 3150 3450 3750 4050 80 130
Gas Pressure (kgf/cm2)
0.65

0.60

0.55

0.50

0.45
80 100 120

Fig. 7.3 Graph of main effect plot for grey relational grade

Figure 7.3 shows that main effect plot for grey relational grade to individual process
parameters.

From figure 7.3 it is clearly shown that it is clearly shown that from 2850 mm/min to 3150
mm/min cutting speed, grey relational grade is increase and from 3150 mm/min to 4050
mm/min cutting speed, grey relational grade is decrease. So, highest grey relational grade
is achieved at 3150 mm/min cutting speed amongst five level of cutting speed.

Now concentrate on effect of pulse frequency on grey relational grade. From figure 7.3 it
is clearly shown that with increase in arc current, grey relational grade is increase. So,
highest grey relational grade is achieved at 130 amp arc current amongst two level of arc
current.

Now concentrate on effect of scanning speed on grey relational grade. From figure 7.3 it is
clearly shown that for increasing gas pressure, grey relational grade is decrease. So,
highest grey relational grade is achieved at 80 kgf/cm2 gas pressure amongst three level of
gas pressure.

80
7.2 Interaction Plots for Process Parameters v/s Response Variables

7.2.1 Interaction effect for surface roughness

Fig. 7.4 Interaction effect of cutting speed and arc current on surface roughness

Fig 7.4 shows an interaction effect of cutting speed and arc current on surface roughness
with taking average gas pressure.

Fig. 7.5 Interaction effect of cutting speed and gas pressure on surface roughness

Fig 7.5 shows an interaction effect of cutting speed and gas pressure on surface roughness
with taking average arc current.

81
 Fig. 7.6 Interaction effect of arc current and gas pressure on surface roughness

Fig 7.6 shows an interaction effect of arc current and gas pressure on surface roughness
with taking average cutting speed.

7.2.2 Interaction effect for material removal rate

Fig. 7.7 Interaction effect of cutting speed and arc current on material removal rate

Fig 7.7 shows an interaction effect of cutting speed and arc current on material removal
rate with taking average gas pressure.

82
Fig. 7.8 Interaction effect of cutting speed and gas pressure on material removal rate

Fig 7.8 shows an interaction effect of cutting speed and gas pressure on material removal
rate with taking average arc current.

Fig. 7.9 Interaction effect of arc current and gas pressure on material removal rate

Fig 7.9 shows an interaction effect of arc current and gas pressure on material removal rate
with taking average cutting speed.

7.3 Summary

In this chapter we have discussed about the various results obtained after experimental
work and also discussed about effect of three process parameters on grey relational grade.
Outcomes of this dissertation work are described in next chapter.

83
 CHAPTER 8
CONCLUSION

In the presented work, experiment are carried out for response variables are surface
roughness and material removal rate with process parameters as cutting speed, arc current
and gas pressure. There are 30 experimental readings taken for all variables to conduct the
parametric study.

For experimental work it will be considered five, two and three levels for process
parameters respectively. Cutting speed is 2850, 3150, 3450, 3750, 4050 mm/min, Arc
current is 80, 130 amp and Gas pressure is 80, 100, 120 kgf/cm2.

Experimental result shows that from 2850 mm/min to 3150 mm/min cutting speed, surface
roughness is decrease and from 3150 mm/min to 4050 mm/min cutting speed, surface
roughness is increase. So it concludes that for achieve good surface quality, cutting speed
must be required less. Now concentrate on effect of arc current on surface roughness, it
concludes that with increase in arc current, surface roughness is decrease. So it concludes
that for achieve good surface quality, arc current required must be more. Now concentrate
on effect of gas pressure on surface roughness, it concludes that with increase in gas
pressure, surface roughness is increase. So it concludes that for achieve good surface
quality, gas pressure must be required less.

Experimental result shows that for material removal rate with increase in cutting speed,
material removal rate is decrease. So it concludes that for achieve good material removal
rate, cutting speed must be required less. Now concentrate on effect of arc current on
material removal rate, it concludes that with increase in arc current, material removal rate
is increase. So it concludes that for achieve good material removal rate, arc current must
be required more. Now talk about effect of gas pressure on material removal rate, it shows
that from 80 kgf/cm2 to 100 kgf/cm2 gas pressure, material removal rate is increase and
from 100 kgf/cm2 to 120 kgf/cm2 gas pressure, material removal rate is decrease. So it
concludes that for achieve good material removal rate, gas pressure must be required less.

From the experimental results for ANOVA analysis it conclude that for surface roughness
percentage contribution of gas pressure is more in three response variables compare to
other two process parameters and for material removal rate percentage contribution of arc
current is more in three response variables compare to other two process parameters.

84
In grey relational analysis total performance of multi objective optimization is depending
on value of grey relational grade. According to performed experiment design, it observed
that the ‘plasma arc cutting process parameters’ setting of experiment no. 10 has the
highest grey relation grade. Thus, the 10th experiment gives the best multi-performance
characteristics among the 30 experiments. From the grey relational analysis it also
conclude that the optimum parameter level for Cutting Speed, Arc Current, Gas Pressure is
(3150 mm/min), (130 amp) and (80 kgf/cm2) respectively.

The results shows its better surface roughness and material removal rate prediction
capabilities and applicability to such industrial plasma arc cutting leading to effective
selection of machining parameter for better qualitative cutting.

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18. Optimizing The Quality Of Parts Manufactured By The Automated Plasma Cutting
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 FUTURE SCOPE

 In this dissertation work, our team has selected three process parameters (cutting speed,
arc current, gas pressure), but in future it may change to another process parameters.
 Here, our team has selected two response variables (surface roughness, material
removal rate), but in but in future it may change to another response variables.
 In this dissertation work, SAILMA material is used with sample size of 100 mm × 100
mm × 6 mm, but other researchers can continue this work with different material as
well as different sample size and thickness.
 In this dissertation work, we selected plasma arc cutting process but in future instead of
this other researcher can select any other manufacturing process.
 In this dissertation work, we have only optimized the process parameters, but in future
we can also predict the machining parameters.
 Using Plasma Arc Cutting system, add the parameter such as Kerf, Voltage, angle,
material dimension, and change advance material such as brass and bronze then
compare the result obtained.
 Using other methodology in the same material of study to compare the results obtained
such as Response Surface Methodology, Weighted Principal Component Analysis, and
Genetic Algorithm etc.
 Also side clearance and thermal effect on material and work piece like Heat Affected
Zone (HAZ) can also be considered to study the effect on properties of work piece.

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 APPENDIX 1

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