IRJET- Optimization of Design Parameters and Nozzle Wear on CNC Plasma Machine by Experimentation

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 497
“OPTIMIZATION OF DESIGN PARAMETERS AND NOZZLE WEAR ON CNC
PLASMA MACHINE BY EXPERIMENTATION”
Mr. Dattu B. Ghane
Lecturer, Department of Mechanical Engineering, Government Polytechnic Awasari, Maharashtra, India
----------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Recently there is consistent research in machining and advancement in innovation. With increment in rivalry in
advertise and to accomplish high exactness now a day the non-traditional machining is moved toward becoming help of any
industry. A standout amongst the most imperative non-customary machining strategies is CNC plasma Machining. Its high
precision, completing, capacity of machining any hard materials and to create mind bogglingshapebuildsitsrequestin showcase.
In proposal work writing has been examined in setting to parametric improvement of CNC plasma Machining. With a specificend
goal to achieve target and ideal outcomes, after find the optimization parameter the moved towered the optimization in size
(design parameters) and minimum wear of nozzle. The fitting orthogonal cluster has been chosen according to number of
components and their levels to perform least experimentation. The work bits of mile Steel materials were utilized for explore
reason. While optimizing a plasma arc cutting nozzle design parameters to minimize the wear, several but selective machine
process parameters and nozzle design parameters given by the various stack holders. This experimentation includes the process
parameters as specifications given by manufacturer, dimensional accuracy report, roughness parameters analysis, material
removal rate analysis and n addition to this, nozzle design parameters after burning the nozzle as, nozzle shell diameter, nozzle
length, nozzle inner shell center pin diameter etc. Experimentation and parameters analysis comes about are given to affirm the
viability of this approach.
Key Words: CNC Plasma, material removal rate, nozzle were, operating parameter, surface roughness etc.
1. INTRODUCTION
The topic for this thesis writing is to Analysis the Process Parameters of CNC Flame Cutting Using Design & Experiment
Techniques. The focus on this project is to obtain an optimum condition (setting)toobtainminiMRRandminimumthesurface
roughness (SR)[1]. A person does not need to be a physicist & chemist to understand the CNC Flame Cutting and Gouging
process. There are four states in which physical matter may be found solid, liquid, gas. Changes from one physical state to
another occur due to, by supplying or subtracting energy, in the form of heat. Water can be used as an example of these four
states of matter. In the solid state it is ice at temperatures of 0 degrees Celsius or colder. With the additionofheat,theicemelts
and changes to water, the liquid state. The addition of more heat to temperatures of 212 degrees F. (100 degrees C.) or hotter)
converts this liquid to its gaseous state, steam.
If you happen to be reading this by the light emitted by a fluorescent lamp you see flame in action. Flame of glowing tube
contains sodium vapor or mercury. It is ionized by a high voltage across electrodes at the ends of the tube and conducts an
electric current which causes the flame to radiate which in turn causes the phosphor coating on theinnersurfaceof thetubeto
glow. For quick cutting of steel plate oxy-acetylene cutting process was preferred. From the last few years’ plasma cutting has
pretty much taken over, for some very good reasons to perhaps most importantly.The plasma cuttingiselectricallyconductive
process [14]. That means that one unit will cut steel, stainless steel, aluminum, copper, bronze, and brass etc.
1.1 Problem Statement
CNC Plasma Arc flamearc cutting can be characterized in terms of two distinct speeds. At cutting speeds on the top of, theflame
jet does not track metal plate. At speeds below, the liquid metal to all-time low of the plate, forming the questionable dross and
the way to properly choose aflame cutting system. The CNC Plasma Arc flamecutting process employsaflametorchwithavery
slender bore to produce a transferred arc to the work piece at a mean current density of within the bore of the torch[6]. The
energy and momentum of thehigh-speedflamejetgeneratedbytheflametorchmelts,vaporizesandremovesthemetalfromthe
region of impingement of the nozzle. By using the CNC Plasma arc cutting it is required to find out the effective way to conduct
the cutting process for mild steel; the most important factors that influence the cuttingprocessandwhatarethebestconditions
to achieve optimum performances to design best specifications and minimum wear of nozzle.

2. PRINCIPLE OF PLASMA CUTTING
Plasma cutting are forms that utilization fuel gases and oxygen to cut metals, individually. French specialists Edmond Fouché
and Charles Picard turned into the first to create oxygen-acetylenecuttingin1903[1]. Pureoxygen,ratherthanair, isutilizedto
expand the fire temperature to permit confined dissolving of the work piece material (e.g. steel) in a room situation. A typical
propane/air fire consumes at around 2,250 K (1,980°C; 3,590 °F), a propane/oxygen fire consumes at around 2,526 K (2,253
°C; 4,087 °F) [3], and an acetylene/oxygen fire consumes at around 3,773 K (3,500 °C; 6,332 °F). Plasma is one of the most
established cutting forms. Still utilized as a part of industry,inlatedecadesithasbeenlessbroadlyusedinmodernapplications
as other particularly conceived advances have been received.
It is still generally utilized for cutting metal plates and tubes, and in addition repairs work. It is likewise as often as possible
appropriate, and supported, for manufacturing a few kinds of metal-based fine art. Also, Plasma has favorable position over
electric cutting procedures in circumstances where getting to power (e.g., by means of an additional line or convenient
generator would show challenges; it is more independent, and, henceforth, frequently morecompact.InPlasma cutting,a light
is utilized to warm metal to its fuel temperature. A surge of oxygen is then prepared on the metal, consuming it into a metal
oxide that streams out of the kerf as slag.
3. EXCPERIMENTAL SET-UP
While doing this the terms like tool magazine capacity, tool life and its availability are taken into consideration. This will be
useful to avoid negative results. The proposed design approachwill providean effective decisionmakingtool forthe shortterm
operational decisions of FMS.
3.3 Controller
The control panel is essential component or part of any CNC machine because it has various switches on it. That is used to
control the various parameter of machine. By the control panel of CNC flame cutting machine we can control the nozzle
movement, flame velocity, gas pressure, air gap as per our need, due to this variousswitcheswecanimproveaccuracyandalso
save our time.
3.4 Sample
Mild Steel material, four quantity samples, having 10 mm thickness and 200 mm x 200 mm size taken for the experiments.
4. METHODOLOGY
Minimum wear of nozzle is found out by the experimentation done on CNC Plasma arc cutting machine. To start the
experimentation firstly optimization of CNCPlasma arccuttingmachinedesign processparametersisdone by experimentation
analysis. Different machine manufacturers and nozzle suppliers suggest differentoperatingparameterstobeused onmachine
for cutting which leads more wear of nozzle. Hence by experimentation on the machine optimize process parameters and
design parameters which gives best results with minimum wear of nozzle for different nozzles as: 1/16; 3/64; 1/32; 5/64.
Figure No.: 3.1: Mass cutting machine
Source: Kalpak Industries, Ahmednagar 2019
3.1 Bed
It is heavy duty massive construction to provide stiffness to
sustain large cutting dynamic force, load of other elements etc.
It is made of high quality granite and it acts as foundation for
all other parts of the machine.
3.2 Gas Bang
A 2-phase approach is developed to solve the tool magazine
arrangement and operations sequencing related problems. By
utilizing the benefits of tool sharing concepts, loading of
duplicate tools, it will lead to decrease the tooling and
operational cost.

5. USED MACHINE PARAMETERS SCENARIO
5.5 Machine operating conditions:
5.5.1 Air Pressure: 110 bar, 5.5.2 Air Filter: 110 bar,
5.5.3 Cooling System: 180C, 5.5.4 Environmental Temperature: 220C,
5.5.5 Current: 227 V, 5.5.6 Vaccum Pressure: 110 bar,
5.5.7 Software: Turbonest, 5.5.8 Operating Language: Hyperthem,
5.5.9 Time required for cutting the sample as per program given from engineering department: 20 Minutes.
6. PARAMETER RESULT
5.1 Operating Parameter used by Industry:
(Kalpak Industries)
Sample
No.
Cutting
Speed
(mm/min)
Oxygen
Pressure
(bar)
LPG
Pressure
(bar)
Air Gap
(mm)
1 400 0.12 0.11 1.50
2 500 0.12 0.12 2.00
3 600 0.12 0.12 1.80
4 700 0.12 0.12 1.10
Table No.: 5.1: Operating Parameters used by Industry:
(Kalpak Industries)
5.2 Operating Parameters taken by
Manufacture: (Mass cutting system machine)
Sample
No.
Cutting
Speed
(mm/min)
Oxygen
Pressure
(bar)
LPG
Pressure
(bar)
Air Gap
(mm)
1 400 0.10 0.11 1.20
2 500 0.12 0.12 1.50
3 600 0.13 0.12 1.60
4 700 0.12 0.12 1.80
Table No.: 5.2: Operating Parameters taken by
Manufacture: (Mass cutting system machine)
5.3 Operating Parameter taken by Nozzle
Provider: (ESAB)
Sample
No.
Cutting
Speed
(mm/min)
Oxygen
Pressure
(bar)
LPG
Pressure
(bar)
Air Gap
(mm)
1 400 0.12 0.11 0.13
2 500 0.12 0.12 0.12
3 600 0.12 0.12 0.12
4 700 0.12 0.12 1.60
Table No.: 5.3: Operating Parameters used by Nozzle
Provider: (ESAB)
5.4 Operating Parameter taken by R & D
Department
Sample
No.
Cutting
Speed
(mm/min)
Oxygen
Pressure
(bar)
LPG
Pressure
(bar)
Air Gap
(mm)
1 400 0.12 0.11 1.2
2 500 0.20 0.12 1.2
3 600 0.11 0.12 1.3
4 700 0.10 0.12 1.2
Table No.: 5.4: Operating Parameters taken by R & D
Department
6.1 Dimensional Analysis Report:
Reading
No.
Sample 1 Sample 2 Sample 3 Sample 4
1 100.33 100.50 100.50 100.20
2 100.50 100.60 100.55 100.23
3 099.99 100.45 100.45 100.20
4 100.60 100.10 100.10 100.01
5 100.10 100.09 100.09 100.02
6 099.91 099.97 099.99 099.99
7 100.45 099.90 099.95 099.98
8 100.60 100.20 100.10 100.03
9 100.70 099.95 099.98 099.99
10 099.89 100.11 100.01 100.01
Mean 100.307 100.192 100.172 100.066
Table No.: 6.1: Dimensional Accuracy Readings
6.2 Roughness Parameters Report:
Roughness
valve
Sample
No. 1
Sample
No. 2
Sample
No. 3
Sample
No. 4
Ra 0.040 0.039 0.030 0.025
Rz 0.020 0.021 0.025 0.020
Rq 0.030 0.026 0.020 0.020
Table No.: 6.2: Roughness Parameters Readings
6.3 Amount of Material Removed (gram):
Reading No.
Sample
No. 1
Sample
No. 2
Sample
No. 3
Sample
No. 4
1 0.040 0.037 0.028 0.020
Table No.: 6.3: Amount of Material Removed Reading

7. SIMULATIONS OF NOZZLE
7.1 Nozzle:
A nozzle is a pipe or tube of varying cross sectional area, and it modify the flow of a fluid, liquid or gas or it will also directs
identical. Spouts square measure regularly won't to the board the speed of stream, speed, heading, mass, shape, and
additionally the weight of the stream that rises up out of them. In a very nozzle, thespeedoffluid will increaseatthe expenseof
its pressure energy. A gas jet, fluid jet, or hydro jet may be a nozzle meant to eject gas or fluid in a very coherent stream into a
close medium. Gas jets square measure ordinarily found in gas stoves, ovens, or barbecues. Gas jets were ordinarily used for
lightweight before the event of electrical lightweight. Alternative varieties of fluid jets square measure found in carburetors,
wherever swish graduated orifices square measure wont to regulate the flow of fuel into associate degree engine, and in
Jacuzzis or spas. Another specialised jet is that the bedded jet. This is often a waterjetthatcontainsdevicestofreethe pressure
and flow, and offers streamline flow, as its name suggests. This offers higher results for fountains. The froth jet is another
variety of jet that uses foam rather than a gas or fluid.
Nozzles used for feeding hot blast into a furnace or forge square measure referred toastubers.Jetnozzlesalsoareemployedin
giant rooms wherever the distribution of air via ceiling diffusers isn't doable or not sensible. Diffusers that use jet nozzles
square measure referred to as jet diffuser wherever it'll be organized withinthefacetwall areassoastodistributeair.Oncethe
temperature distinction between the availability air and therefore the area air changes, the availability air stream is deflected
upwards, to produce heat air, or down, to produce cold air.
7.2 Sample
Mild Steel material, four quantity samples, having 10 mm thickness and 200 mm x 200 mm size taken for the experiments.
7.3 Machine Parameters:
7.3.1 Operating Parameters (Optimized) Used for Optimization of Nozzle Design Parameters as:
Sample No.
Cutting Speed
(mm/min)
Oxygen Pressure
(bar)
LPG Pressure (bar) Air Gap (mm)
4 700 0.12 0.12 1.1
Table No.: 7.3.1: Optimized operating parameters used
7.4 Nozzle Sample Details
The material selected as MS for NOZZLE is EN47. The material properties for design are listed in Table No.:VII.IV.Plaincarbon
steel, chromium vanadium steel, chromium-Nickel-Molybdenum steel, Silicon manganese steel, are the typical materials that
are used in the design of Nozzle as shown in Figure No.: 7.4.1.
7.5 Nozzle Specifications
Parameters Values
Material selected as MS En47
Tensile strength 210GPA
Yield strength 1158MPA
Young’s modulus(E) 1034MPA
Poisson ratio 0266
Density 7700
Table No.: 7.4 - Properties of Nozzle. Figure No.: 7.4.1 - Nozzle details & assembly

8. NOZZLE RESULT ANALYSIS
8.1 Nozzle Design Parameters:
Various nozzle parameters are available based on the nozzle size and plate thicknessasgivenintheTableNo.: 7.5.1,7.5.2,7.5.3
and Table No.: 7.5.4. However 10mm thick mild steel plate is taken for experimentation hence corresponding nozzle
parameters taken as given below in Table No.: 8.1:
Design Parameters
Optimized
Parameters (Process
/CNC)
Nozzle No. 1
(1/16)
Nozzle No. 2
(3/64)
Nozzle No. 3
(1/32)
Nozzle No. 4
(5/64)
Plate Thickness (mm) 10 10 10 10 10
Cutting Speed
(mm/min)
700 700 700 700 700
Acetylene Pressure
(bar)
0.2 0.2 0.2 0.2 0.2
Oxygen Pressure (bar) 0.12 1.5 1.5 1.5 1.5
Propane Pressure (bar) 0.12 1.5 1.5 1.5 1.5
Air Gap (mm) 1.1 1.1 1.1 1.1 1.1
Table No.: 8.1 – Nozzle results analysis
Readin
g No.
Sample 1 Sample 2
Sample 3
Sample 4
1 100.33 100.50 100.50 100.20
2 100.50 100.60 100.55 100.23
3 099.99 100.45 100.45 100.20
4 100.60 100.10 100.10 100.01
5 100.10 100.09 100.09 100.02
6 099.91 099.97 099.99 099.99
7 100.45 099.90 099.95 099.98
8 100.60 100.20 100.10 100.03
9 100.70 099.95 099.98 099.99
10 099.89 100.11 100.01 100.01
Mean 100.307 100.192 100.172 100.066
Table No.: VI.I: Dimensional Accuracy Readings
Nozzle Size: 1/16
Sr. No.
Plate
Thickness
mm
Acetylene
Pressure
(bar)
Propane
Pressure
(bar)
Oxygen
Pressure
(bar)
1 06-10 0.20 1.50 1.50
2 11-15 0.21 1.60 1.40
3 16-20 0.22 1.70 1.30
Table No.: 7.5.1 – Design parameters for nozzle size
1/16
Nozzle Size: 3/64
Sr. No.
Plate
Thickness
mm
Acetylene
Pressure
(bar)
Propane
Pressure
(bar)
Oxygen
Pressure
(bar)
1 06-10 0.20 1.50 1.50
2 11-15 0.21 1.60 1.40
3 16-20 0.22 1.70 1.30
Table No.: 7.5.2 – Design parameters for nozzle
size 3/64
Nozzle Size: 1/32
Sr. No.
Plate
Thickness
mm
Acetylene
Pressure
(bar)
Propane
Pressure
(bar)
Oxygen
Pressure
(bar)
1 06-10 0.20 1.50 1.50
2 11-15 0.21 1.60 1.40
3 16-20 0.22 1.70 1.30
1/32
Nozzle Size: 5/64
Sr. No.
Plate
Thickness
mm
Acetylene
Pressure
(bar)
Propane
Pressure
(bar)
Oxygen
Pressure
(bar)
1 06-10 0.20 1.50 1.50
2 11-15 0.21 1.60 1.40
3 16-20 0.22 1.70 1.30
5/64

9. NOZZLE RESULT ANALYSIS
10. RESULT ANALYSIS AND DISCUSSION
Nozzle
Size
Dimensiona
l Analysis
(Mean)
Roughness Parameters
Amount of
Material
Removed
(gram)
Nozzle
shell
diamete
r: (6mm)
Nozzle length
after burning:
(Length
62.5mm)
Nozzle inner
shell centre pin
diameter: (Dia.
0.90mm)
1/ 16 100.300 Ra-0.020, Rz-0.019, Rq-0.030 0.032 6.12 62.44 0.91
3/ 64 100.034 Ra-0.008, Rz-0.009, Rq-0.021 0.019 6.04 62.48 0.90
1/ 32 100.200 Ra-0.030, Rz-0.025, Rq-0.026 0.026 6.16 62.41 0.91
5/ 64 100.076 Ra-0.021, Rz-0.020, Rq-0.029 0.029 6.14 62.46 0.92
Table No.: 10: Nozzle design parameters result summery
From the experimentation analysis done on PLASMA arc cutting machine as shown in Figure No.: III.I, with sample nozzles as
given in Table No.: X, for dimensional accuracy as given in Table No.: IX.I, roughness parameters as given in Table No.: IX.II,
amount of material removed as given in Table No.: IX.III, nozzle shell diameter as given in Table No.: IX.IV, nozzle length after
burning as given in Table No.: IX.V and nozzle inner shell centre pin diameter as shown in Table No.: IX.VI is conducted. The
above experimentation analysis concludes the 3/64 type nozzle as shown in Figure No.: VII.IV.I, gives the best results in all
respect.
Reading
No.
Sample 1 Sample 2 Sample 3 Sample 4
1 100.21 100.10 100.40 100.21
2 100.49 100.09 100.45 100.19
3 099.97 100.06 100.42 100.18
4 100.62 100.01 100.38 100.16
5 100.11 100.09 100.21 100.01
6 099.93 099.99 100.05 099.99
7 100.47 099.99 099.99 099.98
8 100.61 100.01 100.10 100.02
9 100.71 099.99 099.99 099.99
10 099.88 100.01 100.03 100.02
Mean 100.300 100.034 100.200 100.076
Table No.: 9.1: Dimensional Accuracy Readings
9.4 Nozzle shell diameter: (Dia. 6mm)
Sample No.
1st
Sample
2nd
Sample
3rd
Sample
4th
Sample
Diameter
after
burning
6.12 6.04 6.16 6.14
Table No.: 9.4: Nozzle shell diameter readings
9.5 Nozzle length after burning: (Length 62.5mm)
Sample
No.
1st
Sample
2nd
Sample
3rd
Sample
4th
Sample
Diameter
after
burning
62.44 62.48 62.41 62.46
Table No.: 9.5: Nozzle length after burning readings
9.2 Roughness Parameters Report:
Roughnes
s valve
1st
Sample
2nd
Sample
3rd
Sample
4th
Sample
Ra 0.020 0.008 0.030 0.021
Rz 0.019 0.009 0.025 0.020
Rq 0.030 0.021 0.026 0.029
Table No.: 9.2: Dimensional accuracy readings
9.3 Amount of Material Removed (gram):
Sample No. 1st Sample 2nd Sample 3rd Sample 4th Sample
Amount of Material
removed
0.032 0.019 0.026 0.029
Table No.: 9.3: Amount of material removed readings
9.6 Nozzle inner shell center pin diameter: (Diameter.
0.90mm)
Sample
No.
1st
Sample
2nd
Sample
3rd
Sample
4th
Sample
Diameter
after
burning
0.91 0.90 0.91 0.92
Table No.: 9.6: Nozzle Inner shell centre pin diameter
readings

11. CONCLUSIONS
Literature survey on method parameters of plasma arc cutting has been studied and Experimental work has been
administrated. From that it is concluded that:
1) MRR and surface roughness values are affected bycutting parameterssuchasGaspressureandmaintainedarcgapasshown
in Table No.: 6.2, 6.3, 9.2 and Table No.: 9.3.
2) There are different operating parameters suggested by Kalpak industry, Nozzle provider (ESAB), Mass cutting machine
provider, operating parameters taken by operator and company expert as per expertise (R & D) as given in Table No: 5.1, 5.2,
5.3 and Table No.: 5.4. So among these parameters advised for right parameters selection as given in Table No.: 7.3.1.
3) From Dimensional analysis it is concluded that after cutting, sample width varies at different sections as given in Table No.:
6.1 and Table No.: 9.1.
4) Material removal rate is higher while amount of material removed is less.
5) As the Material removal rate increases the time required to cut the part is less.
6) The surface roughness is having lower value resulting surface finish of part is good that reduces the cost of after processing
operations.
6) In nozzle wear analysis found that the 3/64 type nozzle is the best for all results as shown in Table No.: 10.
REFERENCES
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BIOGRAPHIES
Mr. Dattu Balu Ghane is working as a LecturerintheDepartmentofMechanical EngineeringatGovernment
Polytechnic, Awasari, Pune, Maharashtra, India. He is having wide industrial experience at world leading
research center. He holds a Bachelor and Master degrees in Mechanical Engineering. He has published a
large number of research articles in National and International Journals of high repute. His academic life
includes serving as an AMIE Project Guide, Subject Expert and conducting a number of training programs.
His areas of interest are Automotive Technology Design, Pollution Control, Energy Conservation and
Human Resource Development, Supply Chain Management, Simulation, Lean Manufacturing and Solar
Energy. He has been awarded with various states, national and international awards.

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