Practical and Theoretical Optimization of Plasma Cutting Parameters for Enhanced Quality and Efficiency in Steel Alloy Processing

This study determined the optimal plasma cutting parameters to enhance the quality and efficiency of steel alloy processing. Experiments were conducted on 6 mm thick 09G2S steel alloy using a Kawasaki RS-010L robotic manipulator with a DS 120P.33 inverter power supply. Practical findings revealed that a current of 50 A, voltage of 118 V, cutting speed of 3200 mm/min, and airflow of 1.9 x 10⁻³ m³/s provided the best results, producing a smooth surface, minimal burrs, and a cutting angle within approximately ±4° relative to the surface. The cross-section of the cutting surfaces was analyzed to study the chemical composition across different areas and assess variations caused by the cutting process. Taguchi method was used to find the optimal theoretical parameters, which showed the optimal parameters as 126 V for angle, 118 V for cutting width, 4400 mm/min cutting speed and airflow of 2.3×10−3 m3/s for angle (1.9×10−3 m3/s for cutting width). The microstructure analysis confirmed uniformity in meeting international standards. This research comprehensively analyses cutting conditions and their effects, benefiting metal fabrication by promoting cost-effective, sustainable processes.