ANALYSIS OF WATER PLASMA ARC CUTTING

OF STAINLESS AND MILD STEEL

D.Vaishnavi, R. Lalu Naik, P. NagendraBabu pnb0507@gmail.com 9493360501
Guide: Dr C S Krishna Prasad Rao (Professor), Department of Mechanical Engineering
Bharat Institute of Engineering and Technology
Ibrahimpatnam (Mandal), Ranga Reddy-501510

KEYWORDS USED: Water Plasma Arc Cutting, Stainless steel, Mild steel, Metal Removal Rate,
Current, Voltage, Micro Structure, Thickness, Mechanical strength.

ABSTRACT voltage, current, resistance, hardness at various

This work is about the study and analysis of
the water plasma arc machine for its
applicability and adaptability for cutting of
mild steel and stainless-steel plates of various
thicknesses. For making of this work water
plasma arc machine of prescribed features
have been selected and in addition mild steel
pieces of size 150mm x 150mm x 2mm and
150mm x150mm x 4mm and 150mm x
150mm x 6mm were taken. And stainless steel
of 150mm x 150mm x 2mm, 150mm x 150mm
x 4mm and 150mm x 150 mm 6mm were
taken. At first the machine is conditioned for
cutting process by suitable means of fluids and
parts. For this work Distilled water and
acetone were chosen by 50:50 (v/v) and fed to
the cutting torch. Actually, methanol has to be
used for this purpose however because of non-
availability and non-affordability a similar
kind of liquid acetone is used. Next the M.S.
and S.S. plates are cleaned enough to making
cutting. As the power input and output must be
same based on this the voltage, current and
resistance within the system are calculated
after the initiation of cutting. In addition to this
the angle of torch, direction of cutting,
shielding gas flow rate, time for setting,
holding, cutting, length of cut against time all
these are recorded.
By applying suitable means of formulae
analysis is done. At the end the material
removal rate, time took for cut, angle of torch,
locations, roughness of cut was calculated for
the purpose of further investigation and
optimization of parameters. At the same time
the changes that took place in the work piece
were found such its change in hardness. As
water plasma arc is mainly intended for
making intricate holes but the present work is
focused on cutting using the plasma arc
process. So, by default is adaptability has to be
justified. This work has made an arena by
plotting control charts. At the end the results
and further scope discussed.
CHAPTER- 1
INTRODUCTION
Water plasma arc is used for high quality
joints in the aircrafts, aerospace, chemical and
petroleum industries. The present work
discusses about the weld quality characteristics
of mild steel which are commonly used in
almost all non-specialist steel products like car
domestic goods, constructional steel, street
furniture signs. In this research cutting is
carried out at variable values of input
parameters (current, gas flow) and different
thickness of 2,4 and 6mm for all work pieces.
Current, gas flow is considered as cutting
processes parameters of water plasma arc
process, whereas microstructure, hardness and
tensile properties are considered as weld
quality characteristics.
The water plasma cutting process was
introduced to the cutting industry in 1964 as a
method of bringing better control to the arc
cutting process in lower current ranges. Today,
plasma retains the original advantages it
brought to the industry by providing an
advanced level of control and accuracy to
produce high quality welds in both miniature
and pre precision applications and to provide
long electrode life for high production
requirements at all levels of amperage.
Water plasma cutting is equally suited to
levels of amperage. Water plasma cutting is
equally suited to manual and automatic
applications. It is used in a variety of joining
operations ranging from cutting of miniature
components to seam cutting to high volume
production cutting and many others during
cutting of thin sheets by conventional arc
cutting processes, which offer high heat input
has various problems such as burn through or
plasma flow is initiated by a high frequency
melt trough, distortion porosity as burn
through or melt trough, distortion porosity,
buckling warping and twisting of welded
sheets, grain coarsening evaporation of useful
elements present in coating of the sheets, joint
gap variation during cutting, fume generation
form coated sheets, etc. The selection of
cutting processes parameters play a vital role
in obtaining the desired weld quality hence an
attempt to made to study the weld quality
characteristics (Kondapalli Siva Prasad
etal.,2012.
The present work focuses on studying the
cutting quality characteristics like hardness
and ultimate tensile strength of and
microstructure of plasma arc cut mild steel
plates. Plasma arc cutting is a non-
conventional form of cutting which can be
applied to almost any existing metals. The
various process parameters in plasma arc
cutting such as plasma gas flow rate, torch
height, front weld width, back weld width etc.
play an important role in the prediction of the
weld geometry and quality. Several heat
transfer models have been developed predict
the Weld Geometry. The plasma arc welds
showcase excellent mechanical properties. The
wide range of applications of the plasma arc
cutting ranges from electronics to aerospace
industries. This paper is literature review of
various theoretical and experimental studies by
different researchers over the years. A Section
of the paper also deals with the comparative
review of plasma arc cutting with respect to
other existing forms of cutting processes,
based on existing literature content.
The current from the generator. The ionization
of the gas is taken over by the DC current.
The Different types of PAC processes are as
follows:
1. Micro Plasma Arc Cutting
2. Variable Polarity Plasma Arc Cutting
3. Keyhole Plasma Arc cutting
1.1 Working Principle of Plasma Arc
Cutting
Water Plasma Arc Cutting is the cutting
process utilizing heat generated by a
constricted arc struck between a tungsten non-
consumable electrode and either the work
piece (transferred arc process) or water-cooled
constricting nozzle (non-transferred arc
process). Plasma is a gaseous mixture of
positive ions, electrons and neutral gas
molecules
Transferred arc process produces plasma jet of
high energy density and may be used for high
speed cutting and cutting of Ceramics steels,
Copper alloys titanium alloys, Nickel alloys.
Non transferred arc process produces plasma
of relatively low energy density. It is used for
cutting of various metals and for plasma
spraying (coating). Since the work piece in
non-transferred plasma arc cutting is not a part
of electric circuit, the plasma arc torch may
move from one work piece to other without
extinguishing the arc.
 The scope of this work is experimental study
of the plasma arc cutting in order to identify
the process parameters that influence the most
the quality characteristics of the cut. Four
process parameters were examined, namely the
cutting speed, the cutting current, the plasma
gas pressure and the distance of the plasma
torch from the workpiece surface (cutting
height). The quality characteristics that were
assessed included the surface roughness, the
heat affected zone and the conicity of the cut
geometry. Using design of experiments and
analysis of variance, it was found that the
surface roughness and the conicity are mainly
affected by the cutting height, whereas the heat
affected zone is mainly influenced by the
cutting current.
CHAPTER 2

LITERATURE SURVEY
Experimental research of the water plasma arc
The following literature is studied and
cutting process Dr Anđela Lazarević the
understood for the work to be carried out.
results of the experimental research of water
Various research publications, text books and
plasma cutting process were presented in this
other sources were collected and studied with
paper. The impact analysis of the input process
an emphasis on Plasma arc cutting.
parameters: cutting current (I), cutting speed
(v) and material thickness (s), on the output
process parameters: kerf (sr), surface
Experimental Investigation of the Plasma Arc
roughness (RZ) and bevel angle (β) was done.
Cutting Process K. Salonitisa, *, S.
The plasma cutting machine (CNC) – type
Vatousianosb: The plasma cutting process is
HPm Steel Max 6.25 was used in combination
investigated experimentally in the present
with the water plasma cutting unit – type
paper for assessing the quality of the cut. The
Hypertherm HPR130. The workpiece material
quality of the cut has been monitored by
was stainless steel X10CrNiMn-16-10-2 (EN
measuring the kerf taper angle (conicity), the
10025). Large numbers of cuts were made
edge roughness and the size of the heat-
using the different machine and water plasma
affected zone (HAZ). This work aims at
cutting unit settings. After process data
evaluating processing parameters, such as the
collection, its analysis was done by the
cutting power, scanning speed, cutting height
software application MATLAB. The results
and plasma gas pressure. A statistical analysis
were presented in tables as well as on
of the results has been performed in order for
diagrams, showing particularly dependencies
the effect of each parameter on the cutting
between input and output parameters under
quality to be determined. The regression
various conditions. The objective of this paper
analysis has been used for the development of
was to visualize the influence of input
empirical models able to describe the effect of
parameters on the output parameters, and to
the process parameters on the quality of the
prepare the data for water plasma cutting
cutting.
process modelling, using different methods:
statistical and artificial intelligence.
The experimental research provided data
necessary for further analysis and
considerations of the water plasma cutting
process. This data was used for water plasma
cutting process modelling, using different
methods, while not all data should be used for
every modelling method. Data graphical
representation provided the visual insight in
the dependencies that exist among data.
Metering of the output process parameter s for
different combination of the input parameters
provided the information needed to understand
the water plasma cutting process mechanisms.
However, the software application used for the
process control constrained some variations of
the input parameters in accordance with the
machine manufacturer’s recommendations.
The flexibility in input parameters selection
was limited, and it would be useful for the
further considerations to predict wider ranges
of input parameters changes, for the purposes
of the data analysis and monitoring of
parameters interdependences. This paper
provided visualization of the input parameters
impact to the process output parameters and,
therefore, data preparation for the water
plasma cutting process modelling using
different statistical and/ or artificial
intelligence methods.
Analysis of process parameters of water
plasma arc cutting using design of experiment,
Vivek Singh: In last forty years there is
tremendous research in machining and
development in technology. With increase in
competition in market and to attain high
accuracy now a days the nonconventional
machining are become lifeline of any industry.
One of the most important non-conventional
machining methods is Plasma Arc Machining.
Its high accuracy, finishing, ability of
machining any hard materials and to produce
intricate shape increases its demand in market.
In thesis work literature has been studied in
context to parametric optimization of Plasma
Arc Cutting Machine. In order to attain target
and optimum results, Taguchi method
employed. The appropriate orthogonal array
has been selected as per number of factors and
their levels to perform minimum
experimentation. The work pieces of Stainless
Steel (316 L) materials were used for
experiment purpose. The optimum value has
been determined with the help of main effect
plot and ANOVA table. The Regression
equation for MRR and Surface Roughness
(Ra) has been developed with the help of
Minitab 15 Software. Confirmation test have
done to confirm the value estimated through
the software. The Confirmation for MRR run
was done by using the setting of 5.0 bar (Gas
pressure), 150 A (Current flow rate), 600
mm/min (cutting speed) and 4.0 mm (arc gap).
The optimum parameter level for Surface
Roughness are 6.0 Bar (Gas Pressure), 150 A
(Current), 400 mm/min (Cutting Speed) and 2
mm (Arc Gap). Experimental results are
provided to confirm the effectiveness of this
approach. After the confirmation the MRR
value was 0.8331 g/sec and Ra 2.635µm. Error
within 10 % was allowed.
CHAPTER 3
EXPERIMENT
3.1 EXPERIMENTAL PROCEDURE
Mild steel plates and stainless steel plates of
length l = 150 mm and width = 150 mm and
thickness = 2 mm, 4m and 6mm is cut on
plasma arc cutting machine. The argon gas is
used as shielding gas and a trailing gas right
after cutting to prevent absorption of oxygen
and nitrogen from the atmosphere. The
following observations are made while cutting
the above said pieces.
3.2 Case 1:
Mild steel plate of 150mm x 150mm x 2mm
 89.78 Amps and the mean consumption of
current is 94.17 Amps. And the consumption
is gradually reduced. The maximum
consumption of Voltage is 255 Volts,
minimum consumption of Voltage is 220 Volts
and the mean consumption of Voltage is
239.08 Volts. And the consumption is
gradually increased.

MRR vs time
30
25
20
15
10
After the cutting of the plate the two plates 5
were formed those two were kept aside and 0
left for cooling for some time. Mean while the 0 20 40 60
input parameters were analyzed for the
understanding. Length vs Time
60
50
Current vs Length 40
105 30
20
100 10
95 0
Current 0 5 10 15 20
90

85 The maximum material removal rate (mrr) is

0 10 20 observed at 48th second and its value is 24.22
mm3/s, minimum material removal rate (mrr)
Voltage vs Length is observed at 4th second and its value is 9.82
20 mm3/s. And the mrr is zig-zag. And the cutting
is taking place non linearly. Started from 0th
15
second to 48 seconds.
10
3.7 Finding the Hardness:
5

0 1 2mm On cut 102

200 220 240 260 MS

Fig 1: Current vs Length of 2mm ms Fig 2 2 2mm 5mm 105

Current vs Voltage of 2mm ms plate MS away
from cut
The maximum consumption of current is 100
Amps, minimum consumption of current is
3 2mm 10mm 107 14 6mm 20mm 111
MS away MS away
from cut from cut

4 2mm 20mm 110 15 6mm 30mm 113

MS away MS away
from cut from cut

5 2mm 30mm 112 16 2mm On cut 188

MS away SS
from cut
17 2mm 5mm 191
6 4mm On cut 102 SS away
MS from cut

7 4mm 5mm 104 18 2mm 10mm 195

MS away SS away
from cut from cut

8 4mm 10mm 106 19 2mm 20mm 198

MS away SS away
from cut from cut

9 4mm 20mm 109 20 2mm 30mm 200

MS away SS away
from cut from cut

10 4mm 30mm 114 21 4mm On cut 188

MS away SS
from cut
22 4mm 5mm 191
11 6mm On cut 104 SS away
MS from cut

23 4mm 10mm 195

SS away
12 6mm 5mm 106
from cut
MS away
from cut

13 6mm 10mm 109

MS away
from cut
MICRO STRUCTURE OF THE WORK Mechanical Strength of Plates:
PIECES
The variation of microstructure with respective
of current (amp) and gas flow rate (liters/min) S Para M M MS SS SS SS
shown below. The results shown are different N met S S pla pl pl pla
microstructures obtained at different currents
and gas flow rates. o er pl pl te at at te
at at 6m e e 6m
e e m 2 4 m
Mild At an
steel magnificati 2 4 m m
1 plate of on of
m m m m
2mm 150X
thickne m m
ss
1 Yield 3 36 36 33 33 33
2 Mild At a stre 6 8. 9 0. 1 2
steel magnificati
plate of on of ngth 7 1 1
4mm 150X 2 Tens 3 36 37 67 67 67
thickne
ss ile 6 8. 0 1 1. 3
3 Mild At a
stre 8 5 9
steel magnificati ngth
plate of on of
6mm 150X 3 Red 3 39 40 36 36 37.
thickne ucti 9. .5 2
ss
4 Stainle At a
on 2
ss steel magnificati of
plate of on of
2mm 160X area
thickne 4 Crus 4 45 45 58 58 58
ss
hing 5 7 9 5 5 5
5 Stainle At a
ss steel magnificati stre 5
plate of on of ngth
4mm 180X
thickne 5 Ulti 4 43 43 58 58 58
ss
mat 3 5 8 5 5. 6
6 Stainle At a e 2 4
ss steel magnificati
plate of on of stre
6mm 180X ngth
thickne
ss 6 % 1 14 14. 35 35 34.
Elon 5 .9 92 .5 % 92
gati % % % % %
on
 CONCLUSIONS

Even though cutting process took place

successfully, this process can be further
improved in terms of following.

 Roughness reduction
 Reduction in Power Consumption
 Improvement of surface finish
 Improvement of Material Removal
Rate
All these are achievable if the process
parameters are optimized; hence there is a lot
of scope in this regard for further development
and enrichment.

BIBLIOGRAPHY

1. Dr. Andela Lazarevic,“Experimental

Research of the Water Plasma Arc
Cutting process”, doi: 10.537/jaes12-
6778
2. Srinivas Kadivendi, Meduru
Cahitanya Venkat, Naga Raju Tenali,
“An investigation on weld quality
characteristics of Plasma arc welded
Mild Steel Plates”, International
Journal of Mechanical Engineering
and Robotic Research, Vol 4, Issue 2,
April 2015, ISSN:2278-0419
3. Dr.M. Chithirai Pon Selvan, Nethri
Rammohan and Sampath SS, “Plasma
Arc Welding (PAW) – A literature
Review”, ISSN: 2325-3491
Vivek Singh, “Analysis of Process parameters
of water plasma arc cutting using design of
experiment”, 2011