IJLTEMAS International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS) IJLTEMAS 2278-2540 IJLTEMAS 345 10.51583/IJLTEMAS.2026.150800151 Manufacturing, Optimization Experimental Investigation and Optimization of Process Parameters for Plasma Arc Cutting of Diverse Steel Alloys Kumar Kakati Anjan Department of Mechanical Engineering, Bineswar Brahma Engineering College, Kokrajhar, Assam – 783370, India India Talukdar Gautam Department of Power Electronics and Instrumentation Engineering, Jorhat Institute of Science and Technology, Jorhat, Assam – 785010, India India Pratim Bora Akash Department of Chemical Engineering, Bineswar Brahma Engineering College, Kokrajhar, Assam – 783370, India India 15 8 2082 2096 12 09 2026 17 09 2026 26 09 2026 Material Removal Rate Taguchi Method Process Parameters ANOVA S/N Ratio Abstract

This study optimizes plasma arc cutting parameters to maximize the material removal rate (MRR) for 1.2 mm thick sheets of mild steel, galvanized steel, and AISI 304 stainless steel. The parameters current, voltage, torch distance and pulsing time were optimized using Taguchi L9 orthogonal array. The effects of parameters were analyzed by S/N ratio and ANOVA. The optimum conditions for mild steel, galvanized steel and stainless steel were 85A-120V-3.5mm-1s, 65A-100V-4mm-1s and 65A-100V-4mm-1s. The corresponding MRRs were 2244.4, 1559.4, and 3153.2 mm3/min, respectively. The results show a strong material dependence of the PAC performance and the optimum parameter combinations. The proposed approach offers a practical framework for enhancing cutting productivity and process efficiency

 References Das, P. P., & Chakraborty, S. (2023). A comparative assessment of multicriteria parametric optimization methods for plasma arc cutting processes. Decision Analytics Journal, 6, 100190. Panchal, K. S., & Mungla, M. J. (2020). A review on optimization of plasma arc cutting parameters using Taguchi method for EN19. Journal of Science and Technology, 5(3), 172–191. The Open University. (2018, February 7). Plasma arc cutting. Open Learn. Vasil'ev, K. V. (2003). Plasma-arc cutting: A promising method of thermal cutting. Welding International, 17, 147–151. Xu, W. J., Fang, J. C., & Lu, Y. S. (2002). Study on ceramic cutting by plasma arc. Journal of Materials Processing Technology, 129(1–3), 152–156. Gariboldi, E., & Previtali, B. (2005). High tolerance plasma arc cutting of commercially pure titanium. Journal of Materials Processing Technology, 160(1), 77–89. Gullu, A., & Atici, U. (2006). Investigation of the effects of plasma arc parameters on the structure variation of AISI 304 and St 52 steels. Materials & Design, 27(10), 1157–1162. Bini, R., Colosimo, B. M., Kutlu, A. E., & Monno, M. (2008). Experimental study of the features of the kerf generated by a 200 A high tolerance plasma arc cutting system. Journal of Materials Processing Technology, 196 (1–3), 345–355. Radovanovic, M., & Madic, M. (2011). Modeling the plasma arc cutting process using ANN. Nonconventional Technologies Review, 4, 43–48. Singh, V. (2012). Analysis of process parameters of plasma arc cutting using design of experiment [Doctoral dissertation]. Salonitis, K., & Vatousianos, S. (2012). Experimental investigation of the plasma arc cutting process. Procedia CIRP, 3, 287–292. Chamarthi, S., Reddy, N. S., Elipey, M. K., & Reddy, D. R. (2013). Investigation analysis of plasma arc cutting parameters on the unevenness surface of Hardox-400 material. Procedia Engineering, 64, 854–861. Kavka, T., Mašláni, A., Hrabovský, M., Křenek, P., Stehrer, T., & Pauser, H. (2013). Experimental study of the effect of gas nature on plasma arc cutting of mild steel. Journal of Physics D: Applied Physics, 46(22), 224011. Lazarevic, A. (2014). Experimental research of the plasma arc cutting process. Journal of Applied Engineering Science, 12(4). Das, M. K., Kumar, K., Barman, T. K., & Sahoo, P. (2014). Optimization of process parameters in plasma arc cutting of EN 31 steel based on MRR and multiple roughness characteristics using grey relational analysis. Procedia Materials Science, 5, 1550–1559. Sharma, S., Gupta, M., Kumar, R., & Bindra, N. S. (2017). Experimental analysis and optimization of process parameters in plasma arc cutting machine of EN-45A material using Taguchi and ANOVA method. International Journal of Mechanical and Industrial Engineering, 11(7), 1387–1391. Parthiban, A., Prasath, J. P., Vivek, P., & Pugazhenthi, R. (2018). Experimental investigation of plasma arc cutting for stainless steel sheet. International Journal of Mechanical and Production Engineering Research and Development, 8(1), 907–914. Cinar, Z., Asmael, M., & Zeeshan, Q. (2018). Developments in plasma arc cutting (PAC) of steel alloys: A review. Jurnal Kejuruteraan, 30(1), 7–16. Magid, H. M. (2021). Experimental study of mild steel cutting process by using the plasma arc method. Journal of Achievements in Materials and Manufacturing Engineering, 108(2), 75–85