Prediction and Analysis of Multi-Response Characteristics on Plasma Arc Cutting of Monel 400™ Alloy Using Mamdani-Fuzzy Logic System and Sensitivity Analysis

Abstract

Nickel-based alloys, especially Monel 400™, is gaining its significance in diverse applications owing to its superior mechanical properties and high corrosion resistance. Machining of these materials is extremely difficult through the traditional manufacturing process because of their affinity to rapid work hardening and deprived thermal conductivity. Owing to these difficulties a well-established disruptive metal cutting process namely plasma arc cutting (PAC) can be widely used to cut the sheet metals with intricate profiles. The present work focuses on an intelligent modeling of the PAC process and investigation on the multi-quality characteristics of PAC parameters using the fuzzy logic approach. The Box-Behnken response surface methodology is incorporated to design and conduct the experiments, and to establish the relationship between PAC parameters such as cutting speed, gas pressure, arc current, and stand-off distance and responses which include the material removal rate (MRR), kerf taper (KT), and heat affected zone (HAZ). The quadratic regression models are developed and their performances are assessed using the analysis of variance (ANOVA). Fuzzy set theory-based models are formulated to predict various responses using the Mamdani approach. Fuzzy logic and regression results are compared with the experimental data. A comparative evaluation predicted an average error of 0.04% for MRR, 0.48% for KT, and 0.46% for HAZ, respectively. The effect of variations in PAC process parameters on selected responses are estimated through performing the sensitivity analysis.

Modeling and Optimization of Cut Quality Responses in Plasma Jet Cutting of Aluminium Alloy EN AW-5083

“…Response surfaces and contour plots from Figure 14 show that increase of the arc current results with the increase of the material removal rate. A high concentration of plasma energy is transferred to the workpiece at higher arc current and that leads to quick melting and the vaporization of the metal and higher material removal rate [ 17 ]. At higher cutting speeds the unstable plasma arc is formed [ 6 , 40 ].…”

Optimization of Plasma Arc Cutting Parameters on Machining of Inconel 718 Superalloy

“…to machine Inconel 718 in turning process. Significant factors derive about chipping and tool failure are elevated levels of friction, temperature levels, and contact force during the machining procedure bring about serious sticking and arrangement of BUE (Built-Up Edge) on the instrument external [9,10]. Fontanive et al used micro scale milling assisted with plasma jet at the atmospheric pressure on Inconel 718 to find the process parameters like magnitudes of cutting forces, residual stresses, and surface roughness by using the corresponding techniques.…”

Implementation of the Mamdani Fuzzy Method to Evaluate the Performance of Lecturers in the Research Field

“…(Sadi, 2020) so that the UGN faculty can develop, dedicate and apply their knowledge in research so that it can be upgraded to the intermediate category. (Devaraj et al, 2020) For this reason, an application is needed that can be used to calculate the lecturer's (Hardianto & Nurhasanah, 2020) performance score on the research he produces (Budi Indra Gunawan & Unan Yusmaniar Oktiawati, 2020) To make it easier to see the performance of lecturers (Sofhian et al, 2016) from the research results they produce, the researchers use fuzzy logic applications. (Anisah et al, 2021) Various theories of the development of fuzzy logic show that fuzzy logic can be used to model various systems in general.…”