This article focuses on modeling and optimizing process parameters in pulsed laser micromachining. Use of continuous wave or pulsed lasers to perform micromachining of 3-D geometrical features on difficult-to-cut metals is a feasible option due the advantages offered such as tool-free and high precision material removal over conventional machining processes. Despite these advantages, pulsed laser micromachining is complex, highly dependent upon material absorption reflectivity, and ablation characteristics. Selection of process operational parameters is highly critical for successful laser micromachining. A set of designed experiments is carried out in a pulsed Nd:YAG laser system using AISI H13 hardened tool steel as work material. Several T-shaped deep features with straight and tapered walls have been machining as representative mold cavities on the hardened tool steel. The relation between process parameters and quality characteristics has been modeled with artificial neural networks (ANN). Predictions with ANNs have been compared with experimental work. Multiobjective particle swarm optimization (PSO) of process parameters for minimum surface roughness and minimum volume error is carried out. This result shows that proposed models and swarm optimization approach are suitable to identify optimum process settings.

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Neural Network Modeling and Particle Swarm Optimization (PSO) of Process Parameters in Pulsed Laser Micromachining of Hardened AISI H13 Steel

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Advanced Modeling and Optimization of Manufacturing Processes

Laser beam drilling (LBD) is one of non contact type unconventional machining process that are employed in machining of stiff and high-strength materials, high strength temperature resistance materials such as; metal alloys, ceramics, composites and superalloys. Most of these materials are difficult-to-machine by using conventional machining methods. Also, the complex and precise holes may not be obtained by using the conventional machining processes which may be obtained by using unconventional machining processes. The laser beam drilling in one of the most important unconventional machining process that may be used for the machining of these materials with satisfactorily. In this paper, the attention is focused on the experimental and theoretical investigations on the pulsed Nd:YAG laser drilling of different categories of materials such as ferrous materials, non-ferrous materials, superalloys, composites and Ceramics. Moreover, the review has been emphasized by the use of pulsed Nd:YAG laser drilling of different materials in order to enhance productivity of this process without adverse effects on the drilled holes quality characteristics. Finally, the review is concluded with the possible scope in the area of pulsed Nd:YAG laser drilling. This review work may be very useful to the subsequent researchers in order to give an insight in the area of pulsed Nd:YAG laser drilling of different materials and research gaps available in this area.

Pulsed Nd:YAG laser beam drilling: A review

We propose a simple method to construct a process map for additive manufacturing using a support vector machine. By observing the surface of the built parts and classifying them into two classes (good or bad), this method enables a process map to be constructed in order to predict a process condition that is effective at fabricating a part with low pore density. This proposed method is demonstrated in a biomedical CoCr alloy system. We show that the proposed method is effective at reducing the number of experiments necessary to tailor an optimized process condition. This study also shows that the value of a decision function in a support vector machine has a physical meaning (at least in the proposed method) and is a semi-quantitative guideline for porosity density of parts fabricated by additive manufacturing.

Simple method to construct process maps for additive manufacturing using a support vector machine

Lasers have been used to improve the ultimate performance of thermal spray coatings for specific applications, but the full potential of additional laser treatments must be further explored. Laser treatments (auxiliary processes) can be applied before, during or after thermal spraying (main process), leading to a wide range of coating improvements (microstructure, adhesion, etc.). The aim of this review is to introduce the most significant laser treatments for thermal spray applications. The potential improvements for thermal spray coatings are illustrated by a selection of representative research cases. Laser pretreatments (ablation and texturing) promote coating/substrate adhesion and are suitable to prepare the surface of sensitive substrates such as aluminum, titanium, or magnesium alloys. The use of these techniques, which leads to several benefits such as surfaces free of grit-particle inclusions, directly improves the quality of coatings. Laser treatments applied simultaneously during the spraying process deeply modify the coatings microstructure. These hybrid technologies allow in situ laser melting of coatings, resulting in improved mechanical properties and enhanced wear and corrosion behaviors. Finally, laser posttreatments can improve coatings density and adhesion, and also induce phase transformations and structure refinement. As a summary, laser treatments seem particularly promising for improving the thermal spray coating microstructure and the coating/substrate adhesion. In addition, they offer a more environmentally friendly alternative to the conventional surface preparation treatments.

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S. Bandyopadhyay

Papers

A statistical approach to determine process parameter impact in Nd : YAG laser drilling of IN718 and Ti-6Al-4V sheets