The Optimization Of Laser Machining Parameters For Hole Cutting Of Stainless Steel Using RSM Approaches

Lim, Yong Hock (2019) The Optimization Of Laser Machining Parameters For Hole Cutting Of Stainless Steel Using RSM Approaches. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Broad applications of laser hole cutting in manufacturing industries with the capability of precise cutting are of great importance. In laser hole cutting, the ability to machine a wide range of material types and dimensions are some of the significant advantages compared to other advance machining processing. There are numerous laser micro-hole cutting optimization studies published. Based on those studies, the qualities of laser hole cutting are affected by various process parameters such as laser power, pulse frequency and gas pressure. However, laser hole cutting of hole diameter larger than 5 mm on stainless steel is less studied. Hence, the optimization of the laser hole cutting parameters of 10 mm diameter on stainless steel was studied. The quality characteristics that were taken into considerations in this study are hole taper, surface roughness and heat affected zone, (HAZ) thickness. Visual observation through stereomicroscopes was used to measure HAZ thickness. The average surface roughness, Ra and hole taper were measured by using surface roughness tester and digital caliper respectively. The adopted approach of the experiment was the response surface method (RSM) and the analysis was carried out using Design Expert (trial version) software. The analysis done were ANOVA to identify the significant parameters influencing the process, the main effect, the interaction analysis, and 3D surface analysis. Based on the regression analysis, a polynomial model was developed to predict the output responses based on input parameters. The validations of the polynomial mathematical model were done by comparing the predicted and the experimental output responses. Based on the result of the experiment, the evaluated input parameters, within the range of evaluation settings, do not significantly influence the hole taper. The laser power significantly affecting the surface roughness and HAZ thickness; higher laser power led to wider HAZ thickness and higher surface roughness. The developed linear polynomial model predicting the influence of process parameters to the surface Ra and HAZ thickness were successfully validated with average percentage of error of less than 10%.

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