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Plasma Arc Cutting (PAC) presents a viable alternative for machining thick steel plates, yet optimization studies for plates above 15 mm remain limited. This study applies Response Surface Methodology with Box-Behnken Design (RSM-BBD) to optimize the PAC process parameters for cutting 20 mm thick mild steel S235. The parameters investigated include cutting speed, standoff distance, and gas pressure, with the objective of minimizing surface roughness (Rz5), perpendicularity (u), and Heat-Affected Zone (HAZ) width. Experimental results show that an optimized cutting speed of 1331.44 mm/min, standoff distance of 2.0 mm, and gas pressure of 6.35 bar resulted in a 21.7% improvement in cutting speed efficiency while maintaining an ISO Class 1 roughness and Class 2 perpendicularity. A subsequent optimization aimed at maximizing productivity increased the cutting speed to 1621.51 mm/min, with a minor reduction in desirability (0.818–0.717), but without downgrading the ISO class of cut quality. These findings offer valuable insights into optimizing PAC for thicker plates, providing a structured approach to improving cut quality and efficiency in industrial applications.

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Optimization of PAC Process on Thick Mild Steel with Enhanced Performance

  • 会议论文

  • 发表日期：

    2026年

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  • Zhi-Xian Lim,
  • Nurhafizathul Shamsiah Jamsari,
  • Jie-Wei Wong,
  • Mohd Hasbullah Idris,
  • Tuck-Whye Wong

摘要

Plasma Arc Cutting (PAC) presents a viable alternative for machining thick steel plates, yet optimization studies for plates above 15 mm remain limited. This study applies Response Surface Methodology with Box-Behnken Design (RSM-BBD) to optimize the PAC process parameters for cutting 20 mm thick mild steel S235. The parameters investigated include cutting speed, standoff distance, and gas pressure, with the objective of minimizing surface roughness (Rz5), perpendicularity (u), and Heat-Affected Zone (HAZ) width. Experimental results show that an optimized cutting speed of 1331.44 mm/min, standoff distance of 2.0 mm, and gas pressure of 6.35 bar resulted in a 21.7% improvement in cutting speed efficiency while maintaining an ISO Class 1 roughness and Class 2 perpendicularity. A subsequent optimization aimed at maximizing productivity increased the cutting speed to 1621.51 mm/min, with a minor reduction in desirability (0.818–0.717), but without downgrading the ISO class of cut quality. These findings offer valuable insights into optimizing PAC for thicker plates, providing a structured approach to improving cut quality and efficiency in industrial applications.