Numerical analysis and Schlieren visualization of gas flow dynamics inside the plasma arc cut kerf with curved cutting fronts

In plasma arc cutting (PAC), the characteristics of the gas flow exiting the nozzle significantly influence the cut quality. The high-pressure jet in PAC forms complex shockwave structures when it is incident on the metal to be cut. In this study, the flow behavior inside the kerfs of various geometries derived from an actual PAC workpiece is assessed. The shape of the cutting front in the kerf varies with the changing cutting speed. A high cutting speed yields a curved cutting front, resulting in unwanted gas flow behavior and adversely influencing the cutting performance. In this study, a computational fluid dynamics simulation model was used to analyze the effects of a curved cutting front on the gas flow behavior during the PAC process. The gas flow patterns obtained from the numerical simulations were qualitatively compared with the Schlieren experiment results. The analysis results indicated that the curvature of the cutting fronts generated oblique shockwave structures that significantly reduced the flow velocity. In particular, the weak shock structures throughout the curved cutting front gradually decreased the flow velocity. The critical flow velocity was realized in the kerf with a highly curved cutting front, beyond which the vertical penetration of the material was not possible. The shear stress lines concurred with the striation patterns on the kerf walls, thereby validating the numerical analysis results.