Fabrication of micro holes using low power fiber laser: surface morphology, modeling and soft-computing based optimization

Tuhin Kar; Swarup S. Deshmukh; Arjyajyoti Goswami

doi:10.1007/s40436-024-00484-2

Advances in Manufacturing ›› : 1 -22. DOI: 10.1007/s40436-024-00484-2

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Fabrication of micro holes using low power fiber laser: surface morphology, modeling and soft-computing based optimization

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¹ Department of Mechanical Engineering, National Institute of Technology, Durgapur, India

^c agoswami.me@nitdgp.ac.in

Tuhin Kar is a research scholar in the Department of Mechanical Engineering, National Institute of Technology Durgapur, India. He has received his B.Tech degree from Maulana Abul Kalam Azad University of Technology, West Bengal, India, and M.Tech degree from National Institute of Technical Teachers' Training and Research, Kolkata, India in 2015 and 2019, respectively. His research area includes micro machining, optimization, surface characterization. He has published 8 research papers in various international conferences and journals.

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Swarup S. Deshmukh is a research scholar in the Department of Mechanical Engineering, National Institute of Technology Durgapur, India. He has obtained his Master’s in Mechanical Engineering with a specialization in Production Engineering from Government College of Engineering, Karad India, in 2019. His area of research are non-conventional manufacturing process, optimization technique, and micro-manufacturing process. He has published more than 10 research papers in various international conferences and journals.

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Arjyajyoti Goswami is working as an Assistant Professor in the Department of Mechanical Engineering, National Institute of Technology Durgapur, India. He has completed his Ph.D. from the Indian Institute of Technology, Delhi, and M.Tech from the Delhi Technological University Delhi, India. His interest area includes micro-nano manufacturing, non-conventional machining, nano-particle synthesis by rapid thermal annealing, simulation of nano-structured surfaces, focused ion beam machining, electron beam lithography, welding, and allied processes. He has authored/co-authored over 20 research papers in reputed international journals and refereed conferences.

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Abstract

Fiber laser micromachining is found extensive applications at industrial level because it is cheap and simple to use. Due to its high strength and low conductivity titanium is difficult to machine with conventional methods. In this investigation, micro holes were fabricated using a 30 W fiber laser on 2 mm thick α-titanium (Grade 2) and the process parameters were optimized through response surface methodology (RSM) and teaching learning-based optimization (TLBO) approach. Experimental runs were designed as per rotatable central composite design (RCCD). Material removal rate (MRR), hole circularity (HC), deviation in diameter (DEV) and heat affected zone (HAZ) were selected as output. A third-order polynomial prediction model was established using RSM. Analysis of variance (ANOVA) suggested that the developed model was 93.5% accurate. The impact of input factors on responses were studied by 3D surface plots. RSM desirability indicates that optimum micro drilling conditions are scan speed 275.43 mm/s, frequency 24.61 kHz, power 36.23% and number of passes 49.75. TLBO indicates that optimum micro drilling conditions are scan speed 100 mm/s, frequency 20 kHz, power 20% and number of passes 50. Comparison between RSM and TLBO suggested that TLBO provided better optimization results. Surface morphology of the fabricated micro holes were analyzed with scanning electron microscopy (SEM).

Keywords

Fiber laser / Micro drilling / Response surface methodology (RSM) / Multi objective optimization / Teaching learning-based optimization (TLBO) / Surface morphology

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Tuhin Kar, Swarup S. Deshmukh, Arjyajyoti Goswami. Fabrication of micro holes using low power fiber laser: surface morphology, modeling and soft-computing based optimization. Advances in Manufacturing 1-22 DOI:10.1007/s40436-024-00484-2

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