Optimising the automated plasma cutting process by design of experiments

Asiabanpour, Bahram; Vejandla, D.T.; Jimenez, Jesús A.; Novoa, Clara

doi:10.1504/ijrapidm.2009.028930

Cited by 21 publications

(12 citation statements)

References 7 publications

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“…Karena kebutuhan yang berkembang untuk pembuatan bagian logam fungsional, proses manufaktur yang cepat telah menjadi fokus penelitian dan pengembangan lebih lanjut [1]. Pada tahun 2012, jumlah pengusaha di Indonesia sebanyak 56.539.560 unit.…”

Section: Pendahuluanunclassified

Desain dan Manufaktur Mesin CNC Plasma 3 Sumbu PT. Bangun Mesin Sejahtera

Rahman

2019

JTM

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Pemotongan plasma otomatis adalah proses yang efektif untuk memotong logam dua dimensi yang kompleks dalam waktu singkat. Pengadaan mesin CNC plasma untuk pelaku UMKM pada bidang industri pengolahan pemotongan logam masih tergolong sulit dikarenakan harga yang mahal. Aplikasi DFMA diterapkan dalam menentukan keputusan desain rangka mesin. Desain rangka mesin yang dipilih adalah profil baja dengan material JIS G3466 SKTR490 75mm x 75mm x 2mm dengan tegangan ijin σi = 162,5MPa, sedangkan tegangan bending masksimum σb = 132,83MPa. Selisih hasil analisis perhitungan manual dengan simulasi ANSYS untuk tegangan bending masksimum dan faktor keamanan adalah 0,75MPa dan 0,018. Proses manufaktur yang telah selesai dilakukan menghasilkan mesin CNC plasma yang sesuai standar.

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Section: Pendahuluanunclassified

Desain dan Manufaktur Mesin CNC Plasma 3 Sumbu PT. Bangun Mesin Sejahtera

Rahman

2019

JTM

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“…Therefore, a proper settings to reduce this phenomenon was crucial. 5 The optimised settings required to achieve the best quality are not known, these are not provided by the manufacturers, therefore an investigation and analysis are usually necessary. 6 Some research assumed that plasma was not adequate for any thickness under 1 mm due to quality issues.…”

Section: Introductionmentioning

confidence: 99%

“…Kavka et al 12 assessed experimentally the effect of different gases on the performance of plasma cutting. Asiabanpour et al 5 looked at the possibility to reduce desirability using surface response method using plasma for mild steel 6 mm thick.…”

Section: Introductionmentioning

confidence: 99%

Optimisation of cutting parameters and surface deformation during thin steel sheets plasma processing using Taguchi approach

Gani

Ion

Yang

2021

Advances in Mechanical Engineering

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Plasma machining was investigated for suitability to cut thin sheets and the quality obtained was assessed. The aim of this research was to analyse the impact of the heat generated from plasma cutting on thin sheet surface deformation and heat affected zones. Plasma cutting was assumed to be noneffective for processing thin material, this technology was known primely for cutting medium to thick plates. Tremendous work was performed previously to improve the quality. However, there are no scientific publications assessed the effect of the plasma heat on thin material under 1 mm and optimised optimise the process to reduce the phenomena resulted to their minimal. The traditional cutting methods were found to be limited and time consuming. This research can be beneficial for vehicle convertors such as wheelchair accessible vehicles or similar industries where conventional cutting methods are still predominant. Therefore, an automated plasma cutter if properly optimised would be an effective solution. CNC Plasma cutter with an automated torch height adjustment was used for this experiment to process a 0.6 mm thick deep drawing cold rolled DCO1 steel grade material. Tests were carried out varying the plasma parameters speed, pressure and intensity, the quality obtained was assessed. Three-dimensional Triplescan Atos model was used to measure the maximum surface deformation. Samples were sectioned, mounted, polished, mirrored and etched with 5% Nital acid to expose the material grains. Results were gathered on a tables, then Taguchi method and Analysis of Variance were used to optimise and analyse the parameters. Results showed an effective cut for thin materials. The optimal values obtained were 8000 mm/min, pressure 70 psi and Intensity 25 A for sheet deformation whereas heat affected zones was cutting speed 8500 mm/min, pressure 80 psi and Intensity 30 A. Cutting speed and intensity had the highest impact on deformation however heat affected zones was influenced mainly by the cutting speed. The study suggested also that a mathematical model can be constructed to predict the response for both phenomena and assess the relationship strength, the method used was least square error, the tests showed that the models fit adequately and can be trusted to predict new values. Lastly, a vehicle chassis was used for the test, the results showed an effective cutting on painted material, no second processing was required. Sealant under the material required removal on plasma pathway to avoid excess smoke or fire generation. An estimation was made for the underbody chassis cut out processing time and it was found that automated plasma can reduce the cycle time to just above 40 min.

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“…PAC can be used in cutting of metal plates from approximately 5 to 40 mm thickness. Experimental multi-parameter optimisation of the PAC process according to quality indicators such as kerf characteristics, dimensional accuracy and quality of cut surface have been studied by several researchers in several materials and experimental regions (Gariboldi and Previtali, 2005;Gullu and Atici, 2006;Zhou et al, 2008;Bini et al, 2008;Narimanyan, 2009;Chen et al, 2009;Vejandla, 2009;Asiabanpour et al 2009).…”

Section: Introductionmentioning

confidence: 99%

“…Finally, in MSc thesis (Vejandla, 2009;Asiabanpour et al 2009) the influence of the process parameters of a CNC PAC machine was investigated on cutting of mild steel, and regressions models were extracted for the prediction of several quality indicators.…”

Section: Introductionmentioning

confidence: 99%

A parameter design of CNC plasma-arc cutting of carbon steel plates using robust design

Kechagias¹,

Billis²,

Maropoulos³

2010

IJEDPO

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An optimisation of the cutting parameters during CNC plasma-arc cutting of St37 mild steel plates is attempted using robust design. The process parameters tested were plate thickness, cutting speed, arc ampere, arc voltage, air pressure, pierce height, and torch standoff distance. An orthogonal matrix experiment [L 18 (2 1 × 3 7 )] was conducted and the right bevel angle was measured and optimised according to the process parameters using an analysis of means and an analysis of variances. The results show that the arc ampere has an effect mainly on the bevel angle (50.89%), while the plate thickness and torch standoff distance also have an influence of 6.22 and 15.9% respectively. The other parameters have an F factor smaller than one, and thus their variations do not significantly affect the bevel angle in the experimental region. Finally, an additive model was applied on the experimental results to predict the optimum combination and was compared with actual values.

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Optimising the automated plasma cutting process by design of experiments

Cited by 21 publications

References 7 publications

Desain dan Manufaktur Mesin CNC Plasma 3 Sumbu PT. Bangun Mesin Sejahtera

Desain dan Manufaktur Mesin CNC Plasma 3 Sumbu PT. Bangun Mesin Sejahtera

Optimisation of cutting parameters and surface deformation during thin steel sheets plasma processing using Taguchi approach

A parameter design of CNC plasma-arc cutting of carbon steel plates using robust design

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