Heat affected zone on the micromachined material, a hindrance in achieving good precision and accuracy, which are adequate requirements for micromachined materials, is a drawback of nanosecond micromachining assisted by laser. The primary objective of this paper is to take into consideration a number of input parameters, such as the pulse width and the temperature of the laser beam, and study the effect that these parameters have on the heat flux generated as well as on the temperature distribution along the square grooves of 200 µm width and depth that are to be micro-machined on an alumina ceramic workpiece. However, processing of alumina ceramic on a micron-scale requires careful consideration to raise the quality standard. This will be accomplished by analyzing the data collected from the micro-machining process. Using the ANSYS® software, it is possible to visualize not only the region where heat is generated but also the way in which the input parameters influence the structural qualities of the micro machined groove surface. The many thermal models that have been constructed have revealed specific changes in the structural qualities that have had a significant impact on the upper width, the lower width, and the depth of the groove when applied to a variety of different parametric settings. Finally, developed analytical model is compared with the experimental models. The highest prediction error was found to be 1.68%, while, for constant 50 W power and 150–250 mm/s of speed, the average prediction error was determined to be 1.18%. As a result, the proposed model closely matches the experimental findings, and the proposed model can be used to estimate channel profile.
HsuYJWuHYChangWC,et al.Machining fused silica surface by continuous-wave CO2 laser beams and their nanostructure characterizations. Mater Lett2022; 306: 130960.
2.
WangPZhangZLiuD, et al.Comparative investigations on machinability and surface integrity of CFRP plate by picosecond laser vs laser induced plasma micro-drilling. Opt Laser Technol2022; 151: 108022.
3.
AnjumAShaikhATiwariN. Comparative assessment of the developed algorithm with the soft computing algorithm for the laser machined depth. Infrared Phys Technol2023; 129: 104545.
4.
AbdoBMAEl-tamimiAMAnwarS, et al.Experimental investigation and multi-objective optimization of Nd:YAG laser micro-channeling process of zirconia dental ceramic. Int J Adv Manuf2018; 98: 2213–2230.
5.
PradhanSDhupalD. Machining of aluminium nitride ceramic with a hAJM process using SiC abrasives: experiments and simulation. J Manuf Process2023; 95: 68–90.
6.
PradhanSTripathySSDhupalD. Machining of aluminium nitride ceramic using developed hot abrasive jet machining: an experimental and simulation approach. Adv Mater Process Technol2022; 8: 596–610.
7.
KumarSDhupalDKumarB. Experimental study on Ca3(PO4)2-Al2O3 bio-ceramic composite using DPSS Laser. Mater Today Proc2018; 5: 24133–24140.
8.
WangMYangLZhangS,et al.Experimental investigation on the spiral trepanning of K24 superalloy with femtosecond laser. Opt Laser Technol2018; 101: 284–290.
9.
PradhanSDashPBKumariK,et al.Study of micro machining characteristics by Nd-YAG Laser on NiTinol shape memory alloy. Adv Mater Process Technol2022; 8: 670–684.
10.
AllahyariENivasJJJValadanM, et al.Femtosecond laser surface irradiation of silicon in air: pulse repetition rate influence on crater features and surface texture. Opt Laser Technol2020; 126: 106073.
11.
MuthuramalingamTMoiduddinKAkashR, et al.Influence of process parameters on dimensional accuracy of machined titanium (Ti-6Al-4V) alloy in laser beam machining process. Opt Laser Technol2020; 132: 106494.
12.
PramanikDKuarASSarkarS,et al.Optimisation of edge quality on stainless steel 316L using low power fibre laser beam machining. Adv Mater Process Technol2020; 7: 1–12.
13.
WangXHuangYLiC,et al.Numerical simulation and experimental study on picosecond laser ablation of stainless steel. Opt Laser Technol2019; 127: 106150.
14.
AbdoBMAEl-tamimiAMAnwarS, et al.Experimental investigation and multi-objective optimization of Nd:YAG laser micro-channeling process of zirconia dental ceramic. Int J Adv Manuf Technol2018; 98: 2213–2230.
15.
StaehleRW. Engineering with advanced and new materials. Mater Sci Eng A1995; 198: 245–256.
16.
PanigrahiDRoutSPatelSK,et al.Stray current and its consequences on microstructure of hastelloy C-276 during parametric investigation on geometrical features: fabricated by electrochemical micromachining. Int J Adv Manuf Technol2021; 112: 133–156.
17.
JeevamalarJKumarSBRamuP, et al.Investigating the effects of copper cadmium electrode on inconel 718 during EDM drilling. Mater Today Proc2021; 45: 1451–1455.
18.
FarooqUMAliMSHeY, et al.Curved profiles machining of Ti6Al4 V alloy through WEDM : investigations on geometrical errors. J Mater Res Technol2021; 9: 16186–16201.
19.
DhupalDDoloiBBhattacharyaB. Modeling and optimization on Nd:YAG laser turned micro-grooving of cylindrical ceramic material. Opt Lasers Eng2009; 47: 917–925.
20.
KingreyWDBowenHK. Factors affecting thermal stress resistance of ceramic materials. 2nd ed. NJ, United States: John Wiley & Sons, Inc, 1995.
21.
ModestMF. Transient elastic and viscoelastic thermal stresses during laser scribing of ceramics. United States: Pennsylvania State University, 2015.
22.
MohammedZSaghafifarH. Optimisation of strongly pumped Yb-double doped double-clad fiber lasers using a wide-scope approximate analytical model. Opt Lasers Technol2014; 55: 50–57.
23.
PradhanSDasSRJenaPC,et al.Machining performance evaluation under recently developed sustainable HAJM process of zirconia ceramic using hot SiC abrasives: an experimental and simulation approach. Proc IMechE, Part C: J Mech Eng Sci2021; 236: 1009–1035.
24.
PradhanSDhupalD. Experimental and simulation approach of surface generation on K-80 alumina ceramic by recently developed sustainable FB-HAJM using novel nozzle design. Proc IMechE, Part E: J Process Mech Eng2022; 236: 2502–2514.
25.
PradhanSSahuSDasSR,et al.Experimental study and simulation of surface generation during machining of K-80 alumina ceramic in modified abrasive jet machining with different temperatures using Al2O3 abrasives. Int J Abras Technol2022; 10: 298–329.
26.
KnowlesMRHRutterfordGKamakisD. A ferguson micro-machining of metals, ceramics and polymers using nanosecond lasers. Int J Adv Manuf Technol2007; 33: 95–102.
27.
KhanMUmerUAl-ahmariA. Optimization of Nd:YAG laser for microchannels fabrication in alumina ceramic. J Manuf Process2019; 41: 148–158.
28.
AbdoBMAAhmedNEl-tamimiAM, et al.Laser beam machining of zirconia ceramic: an investigation of micro-machining geometry and surface roughness. J Mech Sc Technol2019; 33: 1–15.
29.
DixitSRPanigrahiDRoutS, et al.A tribological parametric analysis of laser textured microgrooves on Si3N4. Lasers Eng2021; 49: 319–339.
30.
MoscickiTHoffmanJSzymanskiZ. Modeling of plasma formation during nanosecond laser ablation. Conference proceedings of 19th Polish National Fluid Dynamics, Arch Mech 2011; 63, 99-116, Warszawa, Poland.
31.
OttoAKochHVazquezRG, et al.Multi physical Simulation of ns-Laser Ablation of Multi-material LED-Structures. Elsevier B.V(Ed), Proceedings of the 8th International Conference on Photonic Technologies LANE 2014, Physics Procedia 56, 1315-1324, Austria, Portland.
32.
Begic-HajdarevicDBijelonjaI. Experimental and Numerical Investigation of Temperature Distribution and Hole Geometry during Laser Drilling process. Elsevier Ltd(Ed), Proceedings of the 25th DAAAM International Symposium on Intelligent Manufacturing and Automation, Procedia Engg. 2015; 100,. 384-393, Sarajevo, Bosnia & Hergovina.
33.
VolginVMLyubimovVVKukharVD,et al.Modeling of wire electrochemical micromachining. Elsevier B.V(Ed), Proceedings of the CIRP Understanding the life cycle implications of manufacturing, Procedia CIRP 37; 2015, 176-181 Moscow, Russia.
34.
EngelmannCEckstaedtJOlowinskyA, et al.Experimental and simulative investigations of laser assisted plastic metal-joints considering different load directions. Elsevier B.V(Ed), Proceedings of the 9th International Conference on Photonic Technologies LANE, Physics Procedia 2016; 83, 1118-1129, Aachen, Germany.
35.
PradhanSDasSRNandaBK, et al.Machining of hardstone quartz with modified AJM process using hot SiC abrasives: analysis, modelling, optimization, and cost analysis. Surf Rev Lett2021; 28: 2050049.
36.
PradhanSDasSRJenaPC,et al.Experimental investigation and optimization on machined surface of Si3N4 ceramic using hot SiC abrasive in HAJM. Mater Today Proc2021; 44: 1877–1887.
37.
PradhanSDasSRDhupalD. Performance evaluation of recently developed new process HAJM during machining hardstone quartz using hot silicon carbide abrasives: an experimental investigation and sustainability assessment. Silicon2021; 13: 2895–2919.
38.
IlhomSSeyitliyevDKholikovK, et al.Laser shock wave-assisted patterning on NiTi shape memory alloy surfaces. Shape Memory Super Elasticity2018; 4: 224–231. 10.1007/s40830-018-0146-3.
39.
PradhanSDhupalD. An integrated approach of simulation, modeling and computer-aided design of hot abrasive jet machining setup. J Adv Manuf Syst2022; 21: 427–472.
40.
PradhanSTripathySSSahuS, et al.Investigation on MRR and DOC of the micro-holes generated on quartz using silicon carbide by FB-HAJM. 10th International Conference on Materials Processing and Characterization 2020 (ICMPC-2020). vol.26, no.2, pp. 2005-2012, GLA University, Mathura, India.
41.
OliveiraJPMirandaRMSchellN,et al.High strain and long duration cycling behavior of laser welded NiTi sheets. Int J Fatigue2016; 83: 195–200. 10.1016/j.ijfatigue.2015.10.013.
42.
WilhelmERichterCRappBE. Phase change materials in micro actuators: Basics, applications and perspectives. Sens Actuators, A2018; 271: 303–347. 10.1016/j.sna.2018.01.043.
43.
NeurohrAJDunandDC. Shape-memory NiTi with two-dimensional networks of micro-channels. Acta Biomater2011; 7: 1862–1872. 10.1016/j.actbio.2010.11.038.
44.
FarasatiREbrahimzadehPFathiJ,et al.Optimization of laser micromachining of Ti–6Al–4 V. Int J Light Weight Mater Manuf2019; 2: 305–317. 10.1016/j.ijlmm.2019.08.002.
45.
LeiCPanZJianxiongC,et al.Influence of processing parameters on the structure size of micro channel processed by femtosecond laser. Opt Laser Technol2018; 106: 47–51. 10.1016/j.optlastec.2018.03.024.
46.
ChenTCDarlingRB. Laser micromachining of the materials using in microfluidics by high precision pulsed near and mid-ultraviolet Nd:YAG lasers. J Mater Process Technol2008; 198: 248–253. 10.1016/j.jmatprotec.2007.06.083.
47.
KaraziSMIssaABrabazonD. Comparison of ANN and DoE for the prediction of laser-machined micro-channel dimensions. Opt Laser Eng2009; 47: 956–964. 10.1016/j.optlaseng.2009.04.009.
48.
BentonMHossanMRKonariPR,et al.Effect of process parameters and material properties on laser micromachining of micro channels. Micromachines (Basel)2019; 10: 123. 10.3390/mi10020123.
49.
TeixidorDFerrerICiuranaJ,et al.Optimization of process parameters for pulsed laser milling of micro-channels on AISI H13 tool steel. Robot Comp Integ Manuf2013; 29: 209–218. 10.1016/j.rcim.2012.05.005.
50.
ZhuHZhangZXuJ, et al.An experimental study of micro-machining of hydroxyapatite using an ultrashort picosecond laser. Precis Eng2018; 54: 154–162.
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
