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Mooli Harish* et al.

(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

Analysis Of Oxy-Fuel Cutting Process

Parameters Using Grey-Taguchi Technique
For Mild Steel HRE350
MOOLI HARISH P.KUMAR BABU
Assistant Professor, Dept. of Mechanical Engineering Professor, Dept. of Mechanical Engineering
VEMU Institute of Technology, P.Kotha Kota, AP. VEMU Institute of Technology, P.Kotha Kota, AP.
Abstract: The aim of present study is to investigate the effect of process parameters such as Gas pressure,
Cutting speed and Torch distance on the output responses in oxy fuel cutting. The work is also extended
to optimize the process parameters to achieve the optimized responses during oxy fuel cutting of Mild
steel HR E350 using grey taguchi technique.. In this research L27 orthogonal array (OA) was selected for
conducting experiments. The process responses such as Surface roughness (Ra) and kerf width (kw) are
measured for every experimental run. The purpose of optimization is obtaining minimum surface
roughness and minimum kerf width simultaneously. For optimization Grey relational analysis which is
coupled with Taguchi Technique is selected. Analysis of variance (ANOVA) is done for finding significant
process parameters and also for finding percentage of contribution of each process parameters in oxyfuel
cutting. Finally a statistical technique called response surface methodology has been used for study the
effects of the process parameters on surface roughness and kerf width by using design expert 9.0.3.1.
Key words: HRE 350; L27 Orthogonal Array; RSM; Ra And Kerf Width;
I. INTRODUCTION heating the metal to kindling temperature then
passing the stream of oxygen removal of metal
1.1 Oxy-Fuel cutting (OFC)
takes place as an oxide slag to create the kerf.
The oxy fuel cutting process is generally used in
This process is invented in 1887 by Thomas
many metal manufacturing industries. The process
Fletcher is extensively used for cutting steel plates
begins by heating a small area of metal surface to
of various thickness, mainly because the equipment
an ignition temperature by using oxy fuel gas
required is simple and can be carried anywhere
flame. On obtaining ignition temperature of metal
without handling heavy steel plates. Another
the oxygen stream is directed at pre heated spot,
important application of gas cutting is in the
causing rapid oxidation of the heated metal and
making of bevels for edges to be used in
generating large amounts removal of material. Oxy
subsequent welding purpose. Oxy fuel cutting
fuel cutting does not required supporting devices
would be useful only for those materials which
that are fixtures and jigs for holding and guiding
readily get oxidized and the oxides have lower
the work piece because it is a non-contact
melting points than metals. Thus it is most widely
operation. Moreover, it does not need costly or
used for ferrous materials. But it cannot be used for
disposable tools and does not produce mechanical
material such as Aluminium, bronze, stainless steel
force that can damage thin work pieces.
and like metals since they resist oxidation.
For cutting of metallic plates, general purpose
shears are used. These are suitable only straight
line cuts and cuts up to limited thickness. When the
thicker plates and cuts to be made a specified
contour shearing cannot be used. Controls of these
problems we are consider the oxy fuel gas cutting
up to 200mm thickness.
In this process oxidize iron and steel when it is
heated to a temperature between 800°c to 1000°c.
When a high pressure oxygen jet with a pressure of
300kpa is directed against a heated steel plate. The
oxygen jet burns the metal and blows it away Fig1. Schematic diagram of oxy fuel cutting
causing the cut (Kerf).The oxy acetylene gas process
cutting outfit is similar to that of oxy acetylene There are many researchers were studied oxy fuel
welding except for the torch tip. Here the torch tip cutting process. Some of literatures are given
has a provision for preheating the plate as well as below:
providing oxygen jet. Thus the tip has central holes
for preheating flame s shown in figure. That means

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 Mooli Harish* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

[Patricia Muñoz-Escalona et.al]AISI 1045 carbon

steel was cut using oxyacetylene and an
oxypropane cutting process. Different tests, such as
surface roughness, cut drag displacement; groove
width, micro hardness, and microstructure were
used to analyze the influence of the Vc and the
combustion flame (oxyacetylene and oxypropane).
His done the good surface finish is obtained at low
cutting speeds due to characteristics and nature of a
flame. The surface roughness increase while Fig 2: Oxy-fuel cutting equipment
increasing acetylene and propane. By the using of
oxypropane less slag adherence to the cut surface,
the cutting drag displacement decreases and groove
width willbe smaller. Hardness values of cutting
surface are higher when using oxyacetylene.
[N. Osawa, et.al] A genetic algorithm based
technique is used for finding the local heat transfer
coefficient,α andthe gas temperature adjacent to the
plate, TG and HYDROGEN-LP mixed gas and Fig3: Talysurf equipment
LPG are used as preheating gases. In these research
to find time taken to the heating face temperature
to the kindling temp. In these study to find the
piercing time by numerical solutions.
The aim of this research is optimization of control
variables namely gas pressure, Cutting Speed,
torch distance for process responses. The process
responses are surface roughness (Ra) and kerf
width (kw). For obtaining minimum Ra and
minimum kerf width, Grey relational analysis are
coupled with taguchi technique is used in this
research and additionally, ANOVA is performed Fig 4: tool makers’ microscope
on grey Relational grade to determine the
percentage contribution of each control variables 2.2 Selection of work piece material
on grade and finally, RSM technique is employed The Mild steel HRE 350 plate was used as the
for studying process parameters effects on Ra and work piece material in the experiment. Mild steel
K w. HRE350 material is a special engineering material.
II. EXPERIMENTAL PROCEDURE It is highly used in many industries and less
expensive. The key applications of Mildsteel HR
2.1 Experimental setup E350 include making of pipes, nuts and bolts,
Experiment was conducted on the CNC oxy-fuel chains and ship buildings. The chemical
cutting is shown in fig 2. (115/230V and 50-60 composition and mechanical properties of MS
Hz), CNC oxy fuel cutting is comprised of machine HRE 350 is shown in table 1 and table2.
tool, power supply unit, CNC control unit and Table 1: chemical composition (wt. %) of MS HRE 350
machine tool unit. Machine tool unit comprises of
work table, movable parts such as nozzle unit. C Mn S P Si Fe
Work piece is mounted and clamped on the work 0.20 1.55 0.04 0.04 0.45 Balanc
table. The gases used during cutting process are % % % % % e
fuel gas as LPG gas and oxygen gas. For this
research, the experiment was conducted with three Table 2: Mechanical properties of MS HRE 350
control factors namely gas pressure, cutting speed Property Value
and torch height and the process response variables
are surface roughness (Ra) and kerf width (Kw). Tensile strength(MPa) 490
For measuring surface roughness Mitutoyo Yield stress (MPa) 320-350
Talysurf equipment was used is shown in fig. 3
expressed in microns. Kerf width was measured by Percentage of 22%
using tool makers’ microscope. Elongation

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 Mooli Harish* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

2.3. Design of Experiment(DOE) 12 5 300 13 2.38 1.2

Design of experiments (DOE) is one of tool for 13 5 350 7 2.16 1.97
design and conducts the experiments. It is used to 14 5 350 10 2.10 1.46
determine the relation between factors effecting the
process and process responses. Taguchi Technique 15 5 350 13 2.41 1.05
is used to finding the optimized machining process 16 5 400 7 2.27 1.75
parameters in design of experiments. In taguchi
technique the experiments are carried out as per the 17 5 400 10 2.20 1.21
standard orthogonal arrays (OA). The selection of 18 5 400 13 2.4 1.21
orthogonal array depends on the total degree of
freedom (DOF).For the current research, process 19 7 300 7 2.11 2.27
parameters have been selected 3 levels as shown in 20 7 300 10 2.12 1.77
table.3.
21 7 300 13 2.42 1.96
Table 3:Proces parameters and their levels
22 7 350 7 3.03 1.91
Process Units Symbo Levels
23 7 350 10 2.73 1.89
Parameters l
-1 0 1 24 7 350 13 3.09 1.43
Gas Bar A 3 5 7 25 7 400 7 2.84 1.95
pressure
26 7 400 10 2.54 1.77
Cutting mm/ B 300 350 400
Speed min 27 7 400 13 2.71 1.5

3.1. Grey Taguchi technique

Torch Mm C 7 10 13
Distance Grey-Taguchi method is the development from the
Taguchi method. For the optimization of multiple
In the present investigation to check the DOFs in responses Grey Taguchi optimization technique is
the experimental design for the three level test, the employed. By using Taguchi technique we can
three main factors take 6 is (3× (3-1)) DOFs. For optimize process parameters for individual
three second order interactions (A×B, A×C, B×C) responses only. For overcome the disadvantage in
is 12.(3× (3-1) × (3-1)) and the total DOFs required the Taguchi technique, grey-relational analysis is
is 18(6+12). SO L27 OA is selected. coupled with taguchi technique for optimizing
multiple responses.
III. EXPERIMENTAL RESULTS AND
DISCUSSIONS 3.1.1. Grey-relation generation:

The experimental results for process responses Grey relation generation is the first step in the
such as Ra and kerf width is given in table 4. grey-taguchi technique. In this step, the process
response values are normalized in the range of 0-1.
Table4: design of experiment with experimental In this research, Ra and kerf width are the process
results of Ra and Kerf width responses. In general, Ra and kerf width should be
Exp. Gas Cutting Torch Ra Kw minimum for better cu quality, so minimization of
No. Pressure speed Distance surface roughness and minimization of kerf width
is needed. For minimization of process responses
1 3 300 7 1.32 1.51 lower the better criterion is used which is shown in
2 3 300 10 1.49 1.31 eqn. 1. After substituting experimental results we
can get normalized results of Ra and kerf width
3 3 300 13 1.57 0.25 which is given in table 5.
4 3 350 7 1.45 1.17
5 3 350 10 1.57 0.67
6 3 350 13 2.05 0.65
7 3 400 7 1.57 0.75
8 3 400 10 1.69 0.75
9 3 400 13 1.77 0.99
10 5 300 7 1.86 2.22
11 5 300 10 2.36 1.29

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 Mooli Harish* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

Table 5:.normalization of experimental result ‘Ψ’ = distinguish coefficient which is used for,
when Δmax is too large, it helps to weaken its
Exp. No. Normalized Result impact.
Ra Kw
Generally, ‘Ψ’ value in the range of o to 1, for this
1 1 0.376 research, we consider it as 0.5.
2 0.904 0.235
The grey relational coefficient values for Ra and
3 0.859 1
kerf width are given in table 6.
4 0.927 0.27
Table 6:.Grey relational coefficient data for
5 0.859 0.792
normalized values of Ra and Kerf width
6 0.588 0.802
7 0.859 0.752 Exp. No. Grey relational coefficient
8 0.791 0.751 Ra Kw
9 0.746 0.633 1 1 0.445
10 0.695 0.024 2 0.839 0.395
11 0.414 0.48 3 0.780 1
12 0.4 0.52 4 0.873 0.407
13 0.523 0.148 5 0.78 0.706
14 0.558 0.4 6 0.548 0.716
15 0.385 0.6 7 0.78 0.668
16 0.463 0.257 8 0.705 0.668
17 0.502 0.524 9 0.663 0.577
18 0.391 0.524 10 0.621 0.339
19 0.551 0 11 0.460 0.49
20 0.306 0.247 12 0.455 0.51
21 0.38 0.153 13 0.512 0.37
22 0.018 0.175 14 0.531 0.455
23 0.112 0.188 15 0.448 0.556
24 0 0.416 16 0.482 0.402
25 0.078 0.158 17 0.501 0.512
26 0.31 0.247 18 0.451 0.512
27 0.216 0.381 19 0.527 0.333
20 0.419 0.399
Zi (T) = → (1)
21 0.446 0.371
Where Zi (T) = value after grey relation generation, 22 0.337 0.377
Min. = smallest value of the Tth 23 0.36 0.381
response 24 0.333 0.461
25 0.352 0.373
= Largest value of for the Tth
response. 26 0.42 0.399
27 0.389 0.447
3.1.2. Grey relational coefficient:
3.1.3. Grey relational grade and grade order:
The second step in grey relational analysis is the
calculation of grey relation coefficient. Grey Grey relational grade is the third step in grey
relation coefficient are used to express the relation relational analysis. Byaveraging the grey relational
between actual and ideal=1 experimental results. coefficients corresponding to the process response
The grey relation coefficient can be calculated as: values, the grey relational grade is calculated. The
purpose of grey relational grade converting
i (k) = multiple responses into single response values. The
grey relational grade is calculated as:
Where Δ0i=quality loss function=│U0 (M) -Ui (M)
│, Δmin= minimum value of the differences of Δ0i. ᵢ= → (4)
Δmax = Maximum value of the differences of Δ0i. Where n=number of output responses.

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 Mooli Harish* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

The Grey relation grades and their grade orders are

given in table7.
Table 7:Grey relational grade and their order.
Exp. No. Grey relational grade Order
1 0.7225 4
2 0.617 9
3 0.89 1
4 0.64 6
5 0.743 2
6 0.632 7 Fig 5:main effect plot for grade
7 0.724 3
8 0.6865 5 3.3. Analysis of variance (ANOVA):
9 0.62 8 Table 8: Analysis of variance
10 0.48 15
11 0.475 16 Sour D. Seq.S. Seq.M F P %contrib
12 0.4825 13 ce F S. .S. ution
13 0.441 18 A 2 0.436 0.218 47. 0.0 86.1
14 0.493 12 926 463 08 0
15 0.502 11
16 0.442 17 B 2 0.007 0.003 0.7 0.4 1.4
046 523 6 99
17 0.5065 10
18 0.4815 14 C 2 0.003 0.001 0.3 0.7 0.6
19 0.43 19 005 257 2 32
20 0.409 22
A*B 4 0.005 0.001 0.2 0.8 0.9
21 0.4085 23 029 257 7 89
22 0.357 27
23 0.3705 25 B*C 4 0.002 0.005 0.1 0.9 0.4
24 0.397 24 010 03 1 76
25 0.3625 26 A*C 4 0.016 0.004 0.8 0.5 3.2
26 0.4095 21 209 052 7 20
27 0.418 20
3.2. Effects of process parameters on Grade: Erro 8 0.037 0.004 7.3
r 122 640
The main effect plot for grey-relational grade is
given in fig 5. Which is created by using Minitab The ANOVA was used to find out the percentage
17 software? The main effect plots are used to find contribution of each process parameter on the Ra
the individual effects of process parameters on Ra and kerf width is as shown in table 8. ANOVA
and kerf width and also it gives optimized table was created by carrying out the analysis of
condition for obtaining minimum Ra and minimum variance (ANOVA) in Minitab17 software. The
kerf width simultaneously. In the main effect plot higher F-ratio shows more effect and more amount
most significant parameter is one which having of contribution of process parameters on the Ra
highest inclination to the center line. So, it has and kerf width. From the ANOVA table, it is find
more effect on Ra, kerf width. The less significant that pulse on time has the higher percentage of
parameter is one which is being near to the center contribution. % contribution for the factor is the
line. So, it has less effect on Ra and kerf width. ratio between the control factor adjusted sums of
From the main effect plot for means of Grade, gas squares to the total sum of square which is given in
pressure (A) has highest inclination to center line, equ5.
so it is the most significant parameter, and Torch (5)
height(C) has less significant effect which is nearer
to the center line. From the main effect plot, the IV. EFFECT OF CONTROL FACTORS ON
optimized setting for minimum Ra and minimum PROCESS RESPONSES WITH
kerf width during oxy fuel cutting of HRE 350 is SURFACE PLOTS
found to be at A1 B1 C3 i.e. Gas pressure at 3 bar,
cutting speed at 300 mm/min, torch height at 13 In this experiment there are three independent
mm. parameters, which are gas pressure, cutting speed
and torch distance. As a function of the
independent parameters three dimensional surface
plots are drawn for SR and kerf width.

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 Mooli Harish* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

FIG 6.1: surface roughness with cutting speed

and gas pressure .
FIG 6.5: kerf width with cutting speed and torch
distance.

FIG 6.2: surface roughness with cutting speed

and torch distance FIG 6.6:kerf width with torch distance and gas
pressure.
By keeping the one of the three independent
variables as constant, the three dimensional plots
are drawn.fig 5.1 and 5.3 shows that SR increase
rapidly with increase of gas pressure and torch
distance. The reason for this is that large amount of
heat to the work material, so that it will effect the
large amount of heat on work piece. Fig 5.1 and 5.2
shows that SR increases with the increase of
cutting speed. The Reason here for increasing of
SR is that, when speed of nozzle increases the flow
of heating gas on the work material same due to
FIG 6.3: surface roughness with torch distance
these high effect on work piece material and
and gas pressure.
increases the surface roughness. From the Fig 5.4
shows that, kerf width (Ra) increases with the
increase of gas pressure. Because of the large
amount of gas creates the higher removal of
material due to these there will be create the large
distance between base material and cut material
that’s why kerf width will be increases. from the
fig 5.4 and 5.5 the cutting speed increases the kerf
width will be decreases because of the effect of gas
on to the work piece will be decreases. in the case
of torch distance the kerf width will be decreases
because of the effect of flow of gas on to the work
piece will be create less amount these are shown in
FIG 6.4: kerf width with cutting speed and gas fig.5.5 and fig.5.6.
pressure

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 Mooli Harish* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.5, Issue No.2, February – March 2017, 5777-5783.

V. CONCLUSION
1) In this research gas pressure, cutting speed
and torch distance are influencing of oxy fuel
cutting on mild steel HRE 350 are studied.
2) By using grey taguchi method optimum
setting for obtaining the minimum surface
roughness and kerf width is A1 (Gas
pressure, 3 bar), B1 (cutting speed, 300
mm/min), C3 (Torch distance, 13mm).
3) By conducting ANOVA it can be observed
that gas pressure is the more effecting
parameter compared to cutting speed and
torch distance.
4) From the study of three dimensional surface
plots gas pressure, cutting speed and torch
distance are directly proportional to Ra. in the
case of kerf width is directly proportional to
gas pressure and is inversely proportional to
cutting speed and torch distance.
VI. REFERENCES
[1] Patricia Muñoz-Escalona, Maria Carolina
Payares, Minerva Dorta, and Ronald Diaz,
Analysis and Influence of Acetylene and
Propane Gas during Oxyfuel Gas Cutting of
1045 Carbon Steel, ASM International,
1059-9495, submitted February 17, 2006; in
revised form April 5, 2006.
[2] n.osawa, j.sawamura,y.lkegami and
n.okamoto ,study of heat transfer during
piercing process of oxyfuel gas cutting,
Doc. IIW-2152, recommended for
publication by Commission I “Thermal
Cutting and Surfacing.”2012.
[3] Welding, Brazing and Soldering, Vol 6,
ASM Handbook (formerly Metals
Handbook, 9th ed.), ASM International,
1993, p 896.
[4] P. Muñoz-Escalona, M.C. Payares, and
T.Ascanio, “Influence of Gas Type on the
Mechanical Properties of Heat Affected
Zone During oxyfuel Cutting of Carbon
Steel,” presented at ASME Pressure Vessels
and Piping Conference PVP, Atlanta, GA,
Vol 427, 2001, p 129-132.
[5] “Standard Test Method for
Microindentation Hardness of Materials,”
E-384, Annual Book of ASTM Standards,
ASTM, p1-33.

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