Optimization of plasma cutting parameters on HAZ and bevel angle for low carbon steel using response surface methodology

Abstract

The objective of this work is to study the effects of plasma arc cutting process parameters on HAZ(heat affected zone) and Bevel angle for low carbon steel 1010 material with thickness 4 mm, which is used in industries machines lead to low cost and better mechanical strength and used in daily life such as mounting plates, tool and die sets, machinery parts, special bolts. selected three cutting parameters are (arc current, cutting speed and arc distance) For the experimental work. 12 tests will performing each test have one parameter change with four different levels and other parameters are constant. The effect of cutting parameters and predicted equation using second order model depend on experimental results are studied on response results (HAZ and Bevel angle) by using response surface method (RSM). Analyzed of process performance inputs data for different parameters and generated main effect plot of each process parameters on response results by using ANOVA depended on outcomes of response surface methodology. The results of response surface method showed that the major influence parameters were cutting speed and arc current on HAZ (heat affected zone), while the arc distance was major influence parameter on Bevel angle. The response surface method results showed that good agreement between statistical model and the experimental information. The results of response surface method showed that the optimal conditions of cutting parameters to obtain on minimum HAZ (heat affected zone) were (arc current = 90 A, cutting speed = 4000 m/min, arc distance = 3mm) and to obtain on less Bevel angle were (arc current = 90 A, cutting speed = 1000 m/min, arc distance = 3mm).