Experimental Analysis and Optimization of Process Parameters of CNC Plasma Cutting using Taguchi Method for Better Surface and Mechanical Property

Abstract

In today's highly competitive industrial landscape, precision machining plays a crucial role in manufacturing efficiency. CNC plasma arc cutting, a key non-conventional machining process, has gained prominence in smart manufacturing due to its ability to handle complex geometries with high accuracy. A great deal of research has been conducted on CNC Plasma metal cutting, but only few experiments have been carried out to investigate the quality and mechanical properties of ST52 mild steel. This research investigates the influence of key process parameters; cutting current, standoff distance, and cutting speed; on surface quality and mechanical properties of a 6mm thick ST52-3 mild steel using the Taguchi method. Taguchi method using the design of experiments approach can be used to optimize a process. Different input parameters investigated experimentally before the model is built once again and experimentation carried out. MINITAB software used to generate the models and analyse the findings. This contribute to the PAC process operating more effectively and efficiently. The goal is to optimize these parameters to achieve an ideal balance between cut quality and process efficiency. The study employs an experimental approach, utilizing TR100 roughness testing and ANOVA for statistical validation. Results indicate that the optimal parameters for minimum surface roughness (0.028 μm) are 128 A cutting current, 3600 mm/min cutting speed, and 3.5 mm arc gap. Additionally, the best hardness value (821.1 HRB) is obtained at 125 A, 3700 mm/min, and 3.5 mm arc gap. These findings provide valuable insights into CNC plasma cutting optimization.