Parametric Study and Optimization of Nd: YAG Laser Micro-Turning Process of Different Grade of Alumina Ceramics Based on Taguchi Methodology

Abstract

The present paper addresses an investigation on the effect of process parameters during Nd:YAG laser micro-turning operation of different grade of alumina (Al2O3) ceramic materials. Considering different levels of various process parameters i.e. laser beam average power, pulse frequency, workpiece rotational speed and Y feed rate, Taguchi method based experimental design has been used to construct the set of experiments. The same set of experiments has been utilized to machine 10 mm diameter cylindrical workpiece made of different grades of Alumina ceramics i.e. K60 and K80. Surface roughness (Ra) and micro-turning depth deviation were considered as the process characteristics. Analysis of variance (ANOVA) test was performed for each grade of alumina ceramic to find out the significant process parameters during laser micro-turning process. The optimum process parameters settings for individual responses were obtained by analyzing the signal-to-noise (S/N) ratio. Mathematical models, which correlate the response and process variables, have been developed for all the grades of ceramics. Multi-objective optimization i.e. simultaneous minimization of surface roughness (Ra) and micro-turning depth deviation has been done through combined approach of Taguchi methodology and Grey Relational Analysis.