Enhanced decision framework for selecting optimal cutting process for thick metal plates using the CARCACS method

• Enhanced decision framework for cutting process selection using multiple alternatives and criteria. • CARCACS method supports decision-making with integrated weighting and ranking capabilities. • Laser beam cutting ranks highest, surpassing wire EDM with the expanded evaluation criteria. • Punch press cutting ranks third, efficient in some criteria, despite thickness limitations. • Sensitivity analysis confirms the robustness and stability of the top-ranked material alternative. . This study enhances the decision-making framework for selecting cutting processes for thick metal plates by extending an existing decision matrix with an additional cutting process and five evaluation criteria. The revised matrix assesses six processes across thirteen criteria, providing a more thorough evaluation than the prior eight-criterion model. The Criteria-wise Alternative Ranking and Correlation Analysis for Composite Scoring (CARCACS) method, a standalone multi-criteria decision-making (MCDM) tool for criteria weighting and ranking of alternatives, is applied to identify the optimal cutting process. Incorporating additional criteria has led laser beam cutting to the top rank, surpassing the previously leading wire EDM. Both processes remain top alternatives, with rankings shifting according to the criteria considered. Newly incorporated punch press cutting ranks third due to its efficiency in specific criteria, despite limitations in cutting thickness. The study reveals how incorporating additional criteria influences process selection and confirms that the optimal process selection relies on both technical factors and the framework of the decision-making model. Validation through Spearman’s rank correlation and comprehensive sensitivity analyses confirms CARCACS as a reliable and effective decision-support tool for the selection of cutting processes.