Analysis of process parameters of plasma arc cutting using design of experiment

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. In thesis work literature has been studied in context to parametric optimization of Plasma Arc Cutting Machine. In order to attain target and optimum results, Taguchi method employed. The appropriate orthogonal array has been selected as per number of factors and there levels to perform minimum experimentation. The work pieces of Stainless Steel (316 L) materials were used for experiment purpose. The optimum value has been determined with the help of main effect plot and ANOVA table. The Regression equation for MRR and Surface Roughness (Ra) has been developed with the help of Minitab 15 Software. Confirmation test have done to confirm the value estimated through the software. The Confirmation for MRR run was done by using the setting of 5.0 bar (Gas pressure), 150 A (Current flow rate), 600 m/min (cutting speed) and 4.0 mm (arc gap). The optimum parameter level for Surface Roughness are 6.0 Bar (Gas Pressure), 150 A (Current), 400 mm/min (Cutting Speed) and 2 mm (Arc Gap). Experimental results are provided to confirm the effectiveness of this approach. After the confirmation the MRR value was 0.8331 g/sec and Ra 2.635μm. Error within 10 % was allowed.