An integrated analysis of productivity, hole quality and cost estimation of single-pulse laser drilling process

Author:

Sarfraz Shoaib1ORCID,Shehab Essam1,Salonitis Konstantinos1,Suder Wojciech1,Niamat Misbah2,Jamil Muhammad3

Affiliation:

1. Manufacturing Department, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield, Bedfordshire, UK

2. Mechanical Engineering Department, Muhammad Nawaz Sharif University of Engineering and Technology, Multan, Pakistan

3. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China

Abstract

Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to drill a thin-walled Inconel 718 superalloy plate of 1 mm thickness using pulsed Nd:YAG laser. The experiments were designed using Box-Behnken statistical approach to investigate the impacts of pulse energy, pulse duration, gas pressure and gas flow rate on the selected responses. Multi-objective optimisation was performed using response surface methodology (RSM) based grey rational analysis (GRA) to identify optimal drilling conditions aiming to maximise the MRR and minimise hole taper and drilling cost. The optimal combination of drilling parameters was found as pulse energy of 20 J, pulse duration of 6 ms, gas pressure of 100 psi and gas flow rate of 40 mm3/s. A detailed cost analysis identified labour cost, gas consumption and machine costs as the major cost elements of the laser drilling process.

Funder

The Punjab Educational Endowment Fund

Publisher

SAGE Publications

Subject

Industrial and Manufacturing Engineering,Mechanical Engineering

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