Practical and theoretical optimization of plasma cutting parameters for enhanced quality and efficiency in steel alloy processing

Purpose This research aimed to identify the optimal plasma cutting parameters for enhancing the quality and efficiency of steel alloy processing. Systematic experiments, supported by microstructure analyses and the Taguchi method, were conducted to determine the ideal settings for minimizing defects and resource consumption while ensuring high-quality cuts. Design/methodology/approach The study employed a systematic approach to determine optimal plasma cutting parameters for enhancing steel alloy processing. Experiments were conducted using a Kawasaki RS-010L robotic manipulator, powered by a DS 120P.33 inverter power supply. A range of plasma cutting parameters, including current, voltage, cutting speed and airflow, were carefully examined to achieve high-quality cuts while minimizing resource consumption. The Taguchi method was applied to optimize key responses – cutting angle, cutting width and burr formation – providing deeper insights into the influence of each parameter and identifying conditions for further refinement. Findings The study successfully identified the optimal plasma cutting parameters for steel alloy processing. Practical experimentation determined that a current of 50 A, voltage of 118 V, cutting speed of 3,200 mm/min and airflow of 1.9 × 10 –3 m³/s produced a smooth cutting surface, minimal burr formation and a cutting angle within ±4° relative to the surface. The Taguchi method determined optimal settings to minimize angle and cutting width: 126 V, 4,400 mm/min and airflow of 2.3 × 10 –3 m 3 /s for angle and 118 V, 4,400 mm/min and 1.9 × 10 –3 m 3 /s for cutting width. Microstructure analysis confirmed uniformity and conformed to International Organization for Standardization 9013:2002 standards for cut quality. Originality/value This research advances steel alloy processing by combining experimental methods and the Taguchi method to determine optimal plasma cutting parameters for 6 mm thick steel 09G2S, addressing a gap in studies focused on specific materials. Unlike general studies, these results are tailored to low-carbon, low-alloy steels, providing actionable guidance for achieving efficient, high-quality cuts while minimizing waste and improving weldability and ductility. This work contributes to cost-effective and sustainable practices in the metal fabrication industry.