Multi-objective optimization of Nd:Yag laser machining’s conflicting responses while milling micro-channels

Abstract

Laser processing of materials finds application in micro-nano devices mainly because of its accuracy, flexibility, and ability to machine almost any material. Although it offers numerous advantages, it is a complex process involving a large number of factors. The quality of machining often depends on the appropriate selection of parameters. Moreover, the output responses in machining processes have conflicting nature; some are to be minimized, and others have to be maximized. This work uses grey relationship analysis coupled with principal component analysis for multi-response optimization of conflicting responses during laser machining of micro-channels. Micro-channels with a cross-sectional size of 200 × 100 µm were created using Nd:YAG laser beam micro-milling in steel alloy (AISI 1045). The scan speed, layer thickness, and scan strategy were found to have a significant effect on the dimensional accuracy of the microchannel. At the same time, the material removal rate was mostly influenced by layer thickness. Multi-response optimization results suggest low pulse frequency, high scan speed, low layer thickness, and S3 scan strategy for accurately fabricating micro-channels.

Multi-response optimization in laser processing technologies by applying desirability function approach and response surface methodology based on grey relation analysis

“…where Δ oi ( k ) is the absolute difference between comparable sequence y i n ( k ) and reference sequence y o n ( k ) , min Δ oi ( k ) is the smallest value of Δ oi ( k ) and max Δ oi ( k ) is the largest value of Δ oi ( k ) , ξ is the distinguishing coefficient ( ξ ∈ [ 0 , 1 ] ), which is usually taken as 0.5. 15…”

Systematic review of optimization techniques for laser beam machining

“…Stainless Steel[38], Shape Memory Alloys[39], Ti-6Al-4V Alloy[53,62,64,202,203], Tungsten Carbide Alloy[65], Copper[69], Al/Tib2 Nanocomposite[50], Steel Alloy (AISI 1045)[85], Polycrystalline Diamond[204], Monocrystalline Silicon[205], High-Density Polyethylene[61], Cemented Carbides[206], Ceramics[207,208], Nickel Super Alloys[117], Sugar Palm Fiber Reinforced Unsaturated Polyester[52], Domex 700 Steel[209], Sapphire[103], EN-31 Die Steel[51], Gr-Mos2-PI-Carbon Nanotube Nanocomposite[210], Al 7075 Alloy[109], Ti 3Al-2.5V Alloy[78], Inconel Alloy[87], Inconel 718[110,211], Aluminum Alloy (AA 2024)[88], Basalt Fiber Reinforced Polymer[56], Steel[73], Aluminum Alloy[212], Silicon Carbide Particle-Reinforced Aluminum Matrix Composites[79], Titanium Alloy[143,213], Ti10V2Fe3Al Alloy[93], Stainless Steel[214], Glasses[215] AISI H13 Tool Steel[218], Aluminum Titanate (Al2TiO5) Ceramics[91], Ceramics[92], Die Steel[111], Aluminium Oxide (Al2O3) Cer...…”