Analysis of process efficiency in laser fusion cutting and some single- and multi-objective optimization aspects

2021 ◽  
pp. 095440892110627
Author(s):  
Miloš Madić ◽  
Mohamed H Gadallah ◽  
Dušan Petković
Keyword(s):  
Laser Power ◽  
Laser Cutting ◽  
Optimization Problem ◽  
Removal Rate ◽  
Cutting Speed ◽  
Process Efficiency ◽  
Laser Fusion ◽  
Cut Quality ◽  
Dross Formation ◽  
Laser Fusion Cutting

For an efficient use of laser cutting technology, it is of great importance to analyze the impact of process parameters on different performance indicators, such as cut quality criteria, productivity criteria, costs as well as environmental performance criteria (energy and resource efficiency). Having this in mind, this study presents the experimental results of CO2 laser fusion cutting of AISI 304 stainless steel using nitrogen, with the aim of developing a semi-empirical mathematical model for the estimation of process efficiency as an important indicator of the achievable energy transfer efficiency in the cutting process. The model was developed by relating the theoretical power needed to melt the volume per unit time and used laser power, where the change of kerf width was modeled using an empirical power model in terms of laser cutting parameters such as laser power, cutting speed, and focus position. The obtained results indicated the dominant effect of the focus position on the change in process efficiency, followed by the cutting speed and laser power. In addition, in order to maximize process efficiency and simultaneously ensure high cut quality without dross formation, a laser cutting optimization problem with constraints was formulated and solved. Also, a multi-objective optimization problem aimed at simultaneous optimization of process efficiency and material removal rate was formulated and solved, where the determined set of Pareto non-dominated solutions was analyzed by using the entropy method and multi-criteria decision analysis method, that is, the Technique for Order of Preference by Similarity to Ideal Solution. The optimization results revealed that in order to enhance process efficiency and material removal rate, while ensuring high cut quality without dross formation, focusing the laser beam deep into the bulk of material is needed with particular trade-offs between laser power and cutting speed levels at high pressure levels of nitrogen.

Analysis of Laser Cutting of 1.2mm Thick Austenitic Stainless Steel

2020 ◽  
Author(s):  
Asonganyi Ateh Atayo ◽  
Mahmood Bashir ◽  
Muhammad Mustafizur Rahman ◽  
Rajeev Nair
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Laser Power ◽  
Laser Cutting ◽  
Yttrium Aluminum Garnet ◽  
Numerical Study ◽  
Cutting Speed ◽  
Finish Time ◽  
Dross Formation ◽  
Lower Temperature

Abstract Stainless steel 304 is one of the most commonly used steel types for corrosion resistance applications, but higher melting point is a limitation in industries from a manufacturing point of view. The non-conventional and subtractive manufacturing technique of laser cutting — a beam directed method, is suitable for these applications. A Gaussian laser beam is directed at the material that melts, burns, vaporizes, or is blown away by a jet of gas, leaving a fine edge with good surface finish. In this study, a numerical study was performed to study the multi-physical fluid processes of laser cutting. Towards this, modeling was performed using 1.2 mm thick austenitic stainless-steel coupons that was cut using a continuous width neodymium-doped yttrium aluminum garnet (CW Nd: YAG) laser. The results showed smoother surface cut, little dross formation, lower temperature rise in heat affected zones, and less finish time at a cutting speed of 8m/min, higher laser power above 1000 W, gas pressure of 11 bars, and focus distance of −1.0 mm. It was observed that an increase in laser power at a faster cutting speed led to an increase in kerf width, reduction in dross formation, lower temperature rises in heat affected zones and a reduced finish time. The simulation results were compared with published experimental data and found to be well within a maximum difference of 15%.

Quality Analysis of Pulsed Laser Cutting of Superalloy Sheet

2006 ◽  
Vol 315-316 ◽  
pp. 113-117
Author(s):  
S.J. Lv ◽  
Yang Wang ◽  
Shi Jun Ji
Keyword(s):  
Laser Cutting ◽  
Cutting Speed ◽  
Pulsed Laser ◽  
Cutting Parameters ◽  
Recast Layer ◽  
Thin Layers ◽  
Quality Analysis ◽  
Quality Factors ◽  
Cut Quality ◽  
Dross Formation

This paper presents the experiments of Nd:YAG pulsed laser cutting of GH3536 superalloy sheet and investigates the influences of different cutting parameters on laser cut quality factors including recast layer, kerf width and dross formation. The results show that the recast layer possesses finer granularity and higher hardness than those of the matrix, and the thickness of recast layer increases with increased pulse energy and decreases as the cutting speed and gas pressure increase. Oxygen-assisted cutting comes with thick recast layers and argon-assisted cutting acquires thin layers. The low-strength oxide layer worsens the kerf surfaces in oxygen-assisted cutting while argon-assisted cutting produces unaffected surface quality and is suitable for applications with subsequent welding.

scholarly journals Laser Cutting: A Review on the Influence of Assist Gas

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 157 ◽  
Author(s):  
Antonio Riveiro ◽  
Félix Quintero ◽  
Mohamed Boutinguiza ◽  
Jesús Del Val ◽  
Rafael Comesaña ◽  
...  
Keyword(s):  
Gas Dynamics ◽  
Laser Cutting ◽  
Current Knowledge ◽  
Cutting Speed ◽  
Boundary Layer Separation ◽  
Laser Fusion ◽  
Molten Material ◽  
Cut Quality ◽  
Gas Interactions ◽  
Static Conditions

Assist gas plays a central role in laser fusion cutting. In this work, the aerodynamic interactions between the assist gas and the workpiece are reviewed. An insight into those phenomena that hinder the cutting quality and performance is provided. These phenomena include shock waves, choking, boundary layer separation, etc. The most relevant and promising attempts to overcome these common problems related to the gas dynamics are surveyed. The review of the current scientific literature has revealed some gaps in the current knowledge of the role of the assist gas dynamics in laser cutting. The assist gas interactions have been investigated only under static conditions; and the dynamic interaction with the molten material on the cutting front has not been addressed. New nozzle designs with improved efficiency of molten material removal are required to improve cut quality; and cutting speed in current industrial laser cutting machines; especially in those assisted by new high-brightness laser sources.

scholarly journals State-Of-The-Art and Trends in CO2 Laser Cutting of Polymeric Materials—A Review

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3839
Author(s):  
Ray Tahir Mushtaq ◽  
Yanen Wang ◽  
Mudassar Rehman ◽  
Aqib Mashood Khan ◽  
Mozammel Mia
Keyword(s):  
Co2 Laser ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Polymeric Materials ◽  
Pulse Frequency ◽  
Future Research ◽  
Cut Quality ◽  
Dross Formation ◽  
Economical Aspect ◽  
Carbon Dioxide Co2

Carbon dioxide (CO2) laser cutting finds one of its most relevant applications in the processing of a wide variety of polymeric materials like thermoplastics and thermosetting plastics. Different types of polymeric materials like polypropylene (PP), polymethyl methacrylate (PMMA), low- and high-density polyethylene (LDPE, HDPE), are processed by laser for different household as well as commercial products in the industry. The reason is their easy availability and economical aspect in the market. The problems associated with laser cutting include heat-affected zone (HAZ) generated on the cut surface, kerf width (KW), surface roughness (SR), dross formation, and striations formation. Furthermore, other related problems include taper cutting for deep parts and high-power consumption. The primary purpose of this work is a comprehensive literature review in CO2 laser cutting of polymeric materials. The influence of parametric variation on the cut quality is also explained. Cut quality in terms of KW, SR, HAZ, dross formation, and striations formation is analyzed by optimizing cutting variables like laser power (PL), cutting speed (CS), assist gas pressure (Pg), pulse frequency, nozzle type and its diameter, and stand-off distance (SOD). The effects of the laser cutting on the properties of different thermoplastics/thermosetting materials are also reported. However, this topic requires further studies on exploring the range of polymeric materials, and their optimal parameters selection to improve the cut quality. Therefore, the research gaps and future research directions are also highlighted in the context of CO2 laser cutting for polymeric materials.

EXPERIMENTAL STUDY ON THE CO2 LASER CUTTING OF NOVEL POLYAMIDE 6/FLUOROELASTOMER THERMOPLASTIC ELASTOMERIC BLENDS

2015 ◽  
Vol 88 (1) ◽  
pp. 125-137 ◽  
Author(s):  
Shib Shankar Banerjee ◽  
Anil K. Bhowmick
Keyword(s):  
Low Power ◽  
Co2 Laser ◽  
Process Parameters ◽  
Laser Power ◽  
Laser Cutting ◽  
Manufacturing Industry ◽  
Cutting Speed ◽  
Polyamide 6 ◽  
Thermoplastic Elastomers ◽  
Dynamic Vulcanization

ABSTRACT The application of the low-power CO2 laser-cutting process to fluoroelastomer (FKM), polyamide 6 (PA6), PA6/FKM thermoplastic elastomers (TPEs), and their thermoplastic vulcanizate (TPV) is reported. The main laser process parameters studied were laser power, cutting speed, and material thickness. The value of the top and bottom widths of the slit that were formed during laser cutting (kerf width), melted transverse area, and melted volume per unit time were measured and analyzed. Interestingly, TPE showed a smaller melted area and melted volume per unit time when compared with those values with PA6. Dynamic vulcanization further decreased these values. For example, the melted areas of PA6 and TPE were 510 × 10−3 mm2 and 305 × 10−3 mm2, respectively, which reduced to 238 × 10−3 mm2 for TPV at 40 W laser power. FKM showed the lowest value (melted area of 180 × 10−3 mm2). In addition, the output quality of the cut surface was examined by measuring the root mean square (RMS) roughness of the cut edges and heat-affected zone (HAZ). The obtained results indicated that the dimension of the HAZ and RMS roughness largely decreased in TPE when compared with PA6. For example, the HAZ of PA6 was 700 μm, which decreased to 230 μm for TPE at 40 W laser power. On the other hand, HAZ was nonexistent for FKM. Infrared spectroscopic analysis showed that there was no structural change of TPE or pristine polymers after applying the low-power CO2 laser on the surface of materials. CO2 laser cutting will be a new technique in this industry, and this analysis will assist the manufacturing industry to choose a suitable laser system with exhaustive information of process parameters for cutting or machining of rubber, TPEs, and TPVs.

scholarly journals STUDY OF AUXILIARY GAS PRESSURE ON LASER CUTTING TECHNOLOGY

2017 ◽  
Vol 3 ◽  
pp. 163
Author(s):  
Lyubomir Lazov ◽  
Hristina Deneva ◽  
Erika Teirumnieka
Keyword(s):  
Laser Power ◽  
Laser Cutting ◽  
Sheet Steel ◽  
Cutting Speed ◽  
Major Effect ◽  
Gas Pressure ◽  
Experimental Results ◽  
Focus Position ◽  
Angle Deviation ◽  
Basic Parameters

Two types of electrical sheet steel M250-35A and M530-50A were used to cut by melting with a TruLaser 1030 technological system. It was observed that pressure of auxiliary gas had a major effect on kerf width b and cut angle deviation α. Nitrogen as an assisted gas has been taken. The basic parameters as laser power, cutting speed, focus position were constantly supported and the pressure was changed from 4 bar to 20 bar by step 2 bar. As well as the experimental results of gas pressure on entrance and exit kerf widths, have been analyzed and discussed in this study.

scholarly journals Cutting Properties of Austenitic Stainless Steel by Using Laser Cutting Process without Assist Gas

2012 ◽  
Vol 2012 ◽  
pp. 1-8
Author(s):  
Hitoshi Ozaki ◽  
Yosuke Koike ◽  
Hiroshi Kawakami ◽  
Jippei Suzuki
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Molten Metal ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Metallic Materials ◽  
Bottom Side ◽  
Gas Nozzle

Recently, laser cutting is used in many industries. Generally, in laser cutting of metallic materials, suitable assist gas and its nozzle are needed to remove the molten metal. However, because of the gas nozzle should be set closer to the surface of a workpiece, existence of the nozzle seems to prevent laser cutting from being used flexible. Therefore, the new cutting process, Assist Gas Free laser cutting or AGF laser cutting, has been developed. In this process, the pressure at the bottom side of a workpiece is reduced by a vacuum pump, and the molten metal can be removed by the air flow caused by the pressure difference between both sides of the specimen. In this study, cutting properties of austenitic stainless steel by using AGF laser cutting with 2 kW CO2 laser were investigated. Laser power and cutting speed were varied in order to study the effect of these parameters on cutting properties. As a result, austenitic stainless steel could be cut with dross-free by AGF laser cutting. When laser power was 2.0 kW, cutting speed could be increased up to 100 mm/s, and kerf width at specimen surface was 0.28 mm.

A STUDY ON THE SURFACE QUALITIES OF FOUR POLYMER SUBSTRATE MICROCHANNELS USING CO2 LASER FOR MICROFLUIDIC CHIP

2019 ◽  
Vol 26 (03) ◽  
pp. 1850160
Author(s):  
ZENGLIANG HU ◽  
XUEYE CHEN ◽  
YI REN
Keyword(s):  
Polyethylene Terephthalate ◽  
Polymethyl Methacrylate ◽  
Microfluidic Chip ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Processing Parameters ◽  
Polymer Substrate ◽  
Laser Machine ◽  
Polymer Substrates

The paper demonstrates four different polymer substrate microchannels are fabricated by CO2 laser machine. The four different polymer substrates are Polymethyl-methacrylate (PMMA), Polycarbonate (PC), Polystyrene (PS) and Polyethylene Terephthalate (PET), respectively. A number of microchannels are obtained and all roughness is measured. The four different polymer substrate microchannels are processed with different processing parameters. Laser power is set from 4[Formula: see text]W to 32[Formula: see text]W and laser cutting speed is set from 5[Formula: see text]mm/s to 30[Formula: see text]mm/s. The results show the roughness of PS substrate microchannel is lower than that of other three polymer substrate microchannels at the same parameters. When laser power is below 4[Formula: see text]W, the roughness of four polymer substrates are similar. The roughness of different polymer substrate microchannels decreases with the increase of laser power. The roughness of different polymer substrate microchannels also happens to change with increase of laser cutting speed.

EXPERIMENTAL EVALUATION OF CO2 LASER CUTTING QUALITY OF UHSS USING OXYGEN AS AN ASSISTED GAS

2016 ◽  
Vol 78 (7) ◽  
Author(s):  
Abdul Fattah Mohamad Tahir ◽  
Ahmad Razelan Rashid
Keyword(s):  
Co2 Laser ◽  
High Strength Steel ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Speed ◽  
High Strength ◽  
Gas Pressure ◽  
Kerf Width ◽  
Boron Steel ◽  
Major Factors

Development of new material known as Ultra High Strength Steel (UHSS) able to improve the vehicle mass thus reflecting better fuel consumption. Transformation into high strength steel has been a significant drawback in trimming the UHSS into its final shape thus laser cutting process appeared to be the solution. This study emphasizes the relationship between Carbon Dioxide (CO2) laser cutting input parameters on 22MnB5 boron steel focusing on the kerf width formation and Heat Affected Zone (HAZ). Experimental research with variation of laser power, cutting speed and assisted gas pressure were executed to evaluate the responses. Metrological and metallographic evaluation of the responses were made on the outputs that are the kerf width formation and HAZ.  Positive correlation for power and negative interaction for cutting speed were found as the major factors on formation of the kerf. For the HAZ formation, thicker HAZ were formed as bigger laser power were applied to the material. Cutting speed and gas pressure does not greatly influence the HAZ formation for 22MnB5 boron steel.

Laser Cutting Quality of the Ceramic Slabs

2006 ◽  
Vol 505-507 ◽  
pp. 847-852 ◽  
Author(s):  
Xu Yue Wang ◽  
Wen Ji Xu ◽  
Ren Ke Kang ◽  
Yi De Liang
Keyword(s):  
Laser Power ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Incident Laser Power ◽  
Focal Position ◽  
Geometrical Features ◽  
The Relationship ◽  
Cutting System

An experimental analysis is presented which investigates the relationship between cutting parameters and the volume of material removal as well as its cutting quality on a Nd:YAG laser cutting system. The parameters that varied on two testing thickness during cutting include cutting speed, incident laser power and focal position in a continuous through cut. Various trends of the kerf geometrical features in terms of the varying process parameters are analyzed and shown to be reasonable. Discussions are also given on kerf geometry control in situations with cutting parameters. It shows that the effects of varying parameters such as cutting speed, laser power and focal position on cutting kerf width, surface roughness, and striation that have provided a deeper understanding of the laser machining.

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