Factorial Analysis of Fiber Laser Fusion Cutting of AISI 304 Stainless Steel: Evaluation of Effects on Process Performance, Kerf Geometry and Cut Edge Roughness

Abstract

Factorial Design-of-Experiment analyses were applied for conventional and beam oscillation fiber laser cutting of 10 mm thick AISI 304 stainless steel. Considered factors in case of the conventional process with a static beam involve both laser and cutting gas parameters, in particular the laser power, the focal plane position, the cutting gas pressure, the nozzle stand-off distance as well as the nozzle diameter. The conducted trials were evaluated with respect to the achievable cutting speed, the cut kerf geometry and the cut edge roughness. Noticeable correlations between cut edge roughness and cut kerf geometry stimulated the development of a corresponding Computational Fluid Dynamics (CFD) model of the cutting gas flow through the kerf. A specific approach of data synchronization revealed that the experimentally determined roughness values do well correlate with numerically computed values of the backward directed component of the gas-induced shear stress and that the cut kerf geometry as internal process-inherent boundary condition influences relevant cutting characteristics more than controllable external cutting gas parameters. Finally, effects of circular beam oscillation were investigated by an additional factorial analysis considering the laser power, the focal plane position, the oscillation frequency and the oscillation amplitude as factors. The results demonstrate the potential of beam oscillation techniques for quality improvements in laser cutting.

The Effect of Assist Gas Type on Nitinol Microsecond Laser Cut Edges: A Study on the Use of Oxygen, Argon, Nitrogen, Helium, and Compressed Air

“…When the melted material resolidi ed, the surface became more uneven and led to higher arithmetic mean surface roughness measurements. Comparing to the work of Mahrle et al [50] with laser cutting stainless steel, it can be seen that Figure 10-a and Figure 10-c allow for a larger region of melt accumulation that is not expelled from the laser cut surface. As a result, the larger melt accumulation contributes to the increase in surface roughness found at slower cutting speeds.…”

Optimization of nitrogen use efficiency in cutting of austenitic stainless steel by a fiber laser

“…Parameters are usually adjusted by selecting different values for each parameter at which experimental cutting is done. Based on the appearance of cuts, a laser operator decides whether a particular parameter needs further adjustment to achieve the desired effect of cutting [1][2][3].…”

Optimization of Tensile Strength in the Paper Material Cutting Process Based on CO2 Laser Process Parameters

“…Although invented in 1960 [ 1 ], laser technology is still considered to be a new innovative tool in manufacturing industries, and the conventional manufacturing methods remain present and widely used. As a widespread technology with distinguish efficiency and accuracy, as well as a promising future, laser cutting has been extensively applied in the cutting of various materials: wood-based materials [ 2 , 3 ], concrete [ 4 ], cement-based materials [ 5 , 6 ], polymeric materials, such as polymethyl methacrylate [ 7 , 8 , 9 ], polypropylene [ 8 ], and polystyrene [ 10 ], as well as various metallic materials: stainless steel [ 11 , 12 , 13 , 14 , 15 , 16 ], carbon steel [ 17 ], aluminum alloy [ 17 ], and metallic plates [ 18 ]. The first use of the laser in the paper industry dates back to the 1970s, when laser was introduced for perforating cigarette paper, cutting paper, and paperboard [ 19 ].…”