Optimization of gas consumption, cost and production rate for computerized numerical control oxy-acetylene flame cutters

Eustace K. William, Department of Mechanical and Industrial Engineering, University of Dar es Salaam, P.O. Box 35131, Dar es salaam Tanzania.Follow
Simon I. Marandu, Department of Mechanical and Industrial Engineering, University of Dar es Salaam, P.O. Box 35131, Dar es Salaam, TanzaniaFollow
Enock W. Nshama, Department of Mechanical and Industrial Engineering, University of Dar es Salaam, P.O. Box 35131, Dar es salaam Tanzania.Follow

Section

Mathematics and Computational Sciences

Abstract

This study examined the impact of flame cutting parameters (i.e., cutting speed, plate thickness and nozzle diameter) on oxy-acetylene gas consumption, cost and production rate. A full factorial design of experiments was used to generate 27 experiments, which were conducted using a CNC flame cutter. The analysis of variance (ANOVA) method was used to determine significant process parameters, followed by regression analysis using the MINITAB ® software. The technique for order preference by similarity to ideal solutions (TOPSIS) was used to determine the optimal cutting parameters for minimizing the consumption and cost estimation of oxy- acetylene gas and maximizing the production rate. The study found that plate thickness and cutting speed were major contributors to gas consumption variance while nozzle diameter was a minor but significant contributor, where cutting parameter interactions were insignificant. The optimal cutting parameters for 8 and 12 mm thick plates were 700 mm/min cutting speed and nozzle diameters of 0.8 mm or 1.2 mm, respectively. For a 20 mm thick plate, the optimal cutting parameters were 700 mm/min cutting speed and 0.8 mm nozzle diameter. The cost of oxy- acetylene gas and production rate were respectively 0.0604 USD per unit and 1.660 units per minute for 8 mm thick plates, 0.0651 USD per unit and 1.533 units per minute for 12 mm thick plates, and 0.0761 USD per unit and 1.359 units per minute for 20 mm thick plates. Hence, high cutting speed and low plate thickness reduce gas consumption and cutting thinner plates at high speed is cheaper.

Recommended Citation

William, Eustace K.; Marandu, Simon I.; and Nshama, Enock W. (2026) "Optimization of gas consumption, cost and production rate for computerized numerical control oxy-acetylene flame cutters," Tanzania Journal of Science: Vol. 52: Iss. 3, Article 7.
Available at:https://doi.org/10.65085/2507-7961.2327