Mathematical Modeling Approaches and New Development in Laser Micro Machining Process: A Review

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This investigation showed that micro holes were created on Titanium grade 5 substrate surface using a 30 W fiber laser. The impact of the control factors such as scan speed, frequency, number of passes and power were studied on the responses namely heat affected zone (HAZ), hole circularity (HC) and deviation in diameter (DIV). The control factors were optimized using firefly algorithm. Mathematical models were developed for each response having significant R-square value. 3D surface plots were used to examine how the control parameters affected the response. The firefly algorithm identifies the optimal conditions for micro drilling as scan speed of 210 mm/s, frequency of 40 kHz, power of 8 W and total of 40 passes which improved experimental findings i.e. HC-0.974, DIV-37.02 µm and HAZ-19.53. After comparing the predicted values with the experimental findings, it was observed that the prediction error is lowest for HC (1.23 %) followed by DIV (13.9 %) and HAZ (16.9 %). Image processing technique was used to convert regular images into a digital format to extract useful information.

Section: Firefly Algorithm (Fa)mentioning

confidence: 99%

“…Laser micromachining is a precise and efficient machining technique that utilizes a focused laser source to melt and vaporize the substrate. It is a nontraditional method that does not need physical contact with the substrate [3,4]. Laser beam drilling is a high-speed technology that creates accurate holes of micron size.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on fiber laser micro drilling of Titanium grade 5: fabrication, nature-inspired optimization and analysis through image processing

Kar,

Goswami

2024

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“…Various techniques were used to fabricate micro-patterns on mold like lithographic/etching technology, for instance, UV-ray and x-ray lithography [37], plasma etching and electron beam etching [38,39], focused ion beam machining [40], micro-milling [41][42][43], micro-EDM [44], CNC milling [45,46], laser ablation [47][48][49][50][51], etc The combination of micro or nano mold inserts with macro mold tools may be used to produce micro or nano elements. Micro and nano-combined components may be mass-produced; a HE procedure is provided.…”

Section: Micro Hot Embossing Processmentioning

confidence: 99%

A review on modelling and numerical simulation of micro hot embossing process: fabrication, mold filling behavior, and demolding analysis

Datta

Deshmukh²,

Kar³

et al. 2023

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Micro-hot embossing (micro-HE) of polymeric materials creates exact micro/nanoscaled designs. Micro-HE processes include plate-to-plate (P2P), roll-to-roll (R2R), and roll-to-plate (R2P). Micro-HE is preferred for large-scale production of micro-patterns on polymer substrates. However, the lack of simulation models for optimization and component design prevents the broad use of this technology. As the size of the micro patterns decreases from micron to sub-micron, it improves performance features. Micro-HE cannot be analyzed using software tools like injection molding since there is no macroscopic equivalent. Commercial simulation software covers injection molding and associated processes. No commercial tool covers all micro-HE process steps, variations, and boundary conditions. According to the authors, such review articles aren't in the literature. This article summarizes the simulation work in the micro-HE process field related to replication accuracy, and mold filling behaviour. In addition to this, various models were discussed based on properties of material, based on various forces participating in the HE process, and gives a detailed idea about mold-filling behavior and demolding analysis. Finally challenges and future scope related to modelling and simulation work in field of hot embossing has been presented.

“…Because it is a non-contact process, it is useful in industries that need little thermal distortion or damage. This is because it reduces the danger of tool wear and tool damage that is associated with traditional machining methods [9][10][11][12][13].…”

Section: Introduction Of Laser Beam Machiningmentioning

confidence: 99%

Systematic review of optimization techniques for laser beam machining

Kharche,

Patil

2024

Laser Beam Machining (LBM) has several applications in the aerospace, medical, and automobile domains. Optimization techniques are essential for LBM to increase resource-efficiency and sustainability of the system. The present paper aims to provide a systematic review of the research in the domain of optimization techniques for LBM. A total of 228 research papers published during the last 20 years, from 2003 to 2023, are reviewed. The literature review is classified into three major sections- (i) optimization techniques, (ii) applications of optimization techniques, and (iii) challenges and future directions. The novelty of the present systematic review paper is to provide a direction for future research in the domain of optimization techniques of LBM. As a result of the suggested research, an efficient and sustainable LBM with the required performance will be developed in the shortest possible time.