Performance Analysis and Optimization of Plasma Arc Cutting Process for Stainless Steel

Abstract

This research investigates the optimization of plasma arc cutting (PAC) parameters aimed at maximizing material removal rate (MRR) and minimizing surface roughness (Ra) during the cutting of stainless steel (AISI 304). Employing the Taguchi design of experiments (DOE) methodology and Analysis of Variance (ANOVA), four critical control factors—gas pressure, current, cutting speed, and arc gap—were systematically studied at two levels each. The experimental data were analyzed to determine significant factors influencing MRR and surface quality. Regression models were developed, and confirmation experiments validated the optimized parameter combinations. The results demonstrate substantial improvements in both MRR and surface finish, underlining the efficacy of the Taguchi approach in PAC process optimization.