Modeling and Optimization of Cut Quality Responses in Plasma Jet Cutting of Aluminium Alloy EN AW-5083

Abstract

The plasma jet cutting process has a high potential for the machining of aluminium and its alloys. Aluminium is well known as a highly thermally conductive and sensitive material, and because of that there exist uncertainties in defining process parameters values that lead to the best possible cut quality characteristics. Due to that, comprehensive analysis of process responses as well as defining optimal cutting conditions is necessary. In this study, the effects of three main process parameters—cutting speed, arc current, and cutting height—on the cut quality responses: top kerf width, bevel angle, surface roughness Ra, Rz, and material removal rate were analyzed. Experimentations were conducted on aluminium EN AW-5083. In order to model relations between input parameters and process responses and to conduct their optimization, a novel hybrid approach of response surface methodology (RSM) combined with desirability analysis was presented. Prediction accuracy of developed responses regression models was proved by comparison between experimental and predicted data. Significance of process parameters and their interactions was checked by analysis of variance (ANOVA). Desirability analysis was found as an effective way to conduct multi-response optimization and to define optimal cutting area. Due to its simplicity, the novel presented approach was demonstrated as a useful tool to predict and optimize cut quality responses in plasma jet cutting process of aluminium alloy.

Artificial Intelligence Fuzzy Logic Modeling of Surface Roughness in Plasma Jet Cutting Process of Shipbuilding Aluminium Alloy 5083

“…From Figure 9 it can be observed that cutting speed and arc current are the most significant parameters that affect surface roughness responses while gas pressure and cutting height have lower influence. Surface roughness formation in plasma jet cutting process is mainly determined by molten metal fluctuation, plasma jet flow perturbation, cutting torch vibration and motion of anode spots within the groove of cut [4,17]. Figure 9 shows that increase of the cutting speed results with lower surface roughness values.…”

“…In principle, at high cutting speeds (6000 mm/min) increase of the arc current results with the slightly lower surface roughness. In this situation higher energy input and more intensive fluctuation of the molten aluminium result with the lower surface roughness [4,17].…”

“…Partial swarm optimization algorithm was applied to define optimal process parameters values that result with minimal heat affected zone. Peko et al [4] applied regression analysis combined with ANOVA to define mathematical models that describe the influence of process parameters cutting speed, arc current and cutting height on cut quality responses kerf width, bevel angle, surface roughness Ra, Rz and material removal rate. They conducted experimental trials on aluminium alloy 5083 thickness 3 mm.…”

“…Finally, response surface plot was created to analyse process parameters effects and to define optimal cutting speed and arc current values where surface roughness is minimal. Peko et al [8] applied artificial intelligence fuzzy logic technique to establish functional relations between inputs, process parameters: gas pressure, cutting speed, arc current and cutting height and output dross height cut quality response. AI fuzzy logic model was generated according to results obtained in experimentations.…”

Development of plasma cutting technique for C1220 copper, AA2024 aluminum alloy, and Ti-1,5Al-1,0Mn titanium alloy using a plasma torch with reverse polarity

“…Методы оптимизации параметров режима подразумевают под собой применение различных методов математического моделирования, устанавливающих связь между геометрическими и структурными параметрами материала в области реза и рядом параметров режима процесса резки. Среди основных параметров, определяющих качество реза, рассматриваются ток и напряжение плазменной дуги, высота резки, скорость резки [15][16][17].…”