Optimizing the Quality of Parts Manufactured by the Automated Plasma Cutting Process Using Response Surface Methodology

Automated plasma cutting is an effective process for building complex two-dimensional metallic parts in a short period of time. Because the plasma cutting machine has several factors or input variables to control (e.g., current, cutting speed, torch height) and a variety of part quality characteristics or response variables to satisfy (e.g., flatness, clean cut, bevel angle), it is very difficult to find an overall optimum machine setting. In this research, response surface methodology and desirability functions are used to simultaneously optimize 18 part quality characteristics. Final results identify an optimal machine configuration that facilitates the fabrication of parts with close-to-perfect quality for all responses considered.