Investigation and optimization of plasma arc cutting process parameters for AISI 304 by integrating principal component analysis and composite desirability method

Improving and controlling the quality of cuts is one challenging task during plasma arc cutting of stainless steel. Therefore, the present study aims to investigate and optimize the cutting process parameters of plasma arc cutting (PAC) of AISI 304. Plasma arc cutting has wide industrial applications due to its precision of cuts at low cost and high speed. An integrated approach of the Taguchi method, principal component analysis, and composite desirability method is adopted to investigate and optimize the PAC parameters. The cutting parameters considered are arc current, arc voltage, cutting speed, and torch height, while the responses are surface roughness profile, material removal rate, kerf width, and dross. A total of 27 experiments are performed using Taguchi orthogonal array design. The analysis of variance results revealed that torch height has a significant effect on all considered responses. The optimized parameters obtained are arc current 40 A, arc voltage 180 V, cutting speed 1400 mm/min, and torch height 3 mm. The present study will assist industrial practitioner in selecting, controlling, and optimizing PAC process parameters to acquire the excellent cut quality with high productivity, minimal material wastage, and diminished the deposition of tenacious resolidified metal.