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Effect of laser parameters on sequential laser beam micromachining and micro electro-discharge machining

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Abstract

Laser beam micromachining (LBMM) and micro electro-discharge machining (μEDM) based sequential micromachining technique, LBMM-μEDM, has drawn significant research attention to utilize the advantages of both methods, i.e., LBMM and μEDM. In this process, a pilot hole is machined by the LBMM, and subsequently finishing operation of the hole is carried out by the μEDM. This paper presents an experimental investigation on the stainless steel (type SS304) to observe the effects of laser input parameters (namely, laser power, scanning speed, and pulse frequency) on the performance of the finishing technique, that is, the μEDM in this case. The scope of the work is limited to 1-D machining, i.e., drilling microholes. It was found that laser input parameters mainly scanning speed and power influenced the output performance of μEDM significantly. Our study suggests that if an increased scanning speed at a lower laser power is used for the pilot hole drilling by the LBMM process, it could result in significantly slower μEDM machining time. On the contrary, if the higher laser power is used with even the highest scanning speed for the pilot hole drilling, then μEDM processing time was faster than the previous case. Similarly, μEDM time was also quicker for LBMMed pilot holes machined at low laser power and slow scanning speed. Our study confirms that LBMM-μEDM-based sequential machining technique reduces the machining time, tool wear, and instability (in terms of short circuit count) by a margin of 2.5 x, 9 x, and 40 x, respectively, in contrast to the pure μEDM process without compromising the quality of the holes.

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Acknowledgement

First of all, we thank Allah (SWT) for providing us with the ability to conduct this research. The authors also acknowledge the research support provided by the International Islamic University Malaysia. We also thank the Ministry of Higher Education Malaysia and the Asian Office of Aerospace Research and Development for their generous funding to carry out this research.

Funding

This project was funded by research grants provided by the Ministry of Higher Education Malaysia (MOHE Grant No: FRGS/1/2018/TK03/UIAM/02/2) and Asian Office of Aerospace Research and Development (AOARD Grant No: BAA-AFRL-AFOSR-2016-0007). In particular, Mir Akmam Noor Rashid was paid as a graduate research assistant (GRA) from the MOHE grant, and Wazed Ibne Noor was paid as a graduate research assistant from the AOARD grant.

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Authors and Affiliations

  1. Autonomous Systems and Robotics Research Unit (ASRRU), Department of Mechatronics Engineering, International Islamic University Malaysia, 53100, Kuala Lumpur, Malaysia

    Mir Akmam Noor Rashid, Tanveer Saleh & Wazed Ibne Noor

  2. School of Electrical Engineering, Universiti Teknologi Malaysia, 81310 UTM, Johor Bahru, Johor, Malaysia

    Mohamed Sultan Mohamed Ali

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  1. Mir Akmam Noor Rashid
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  2. Tanveer Saleh
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  3. Wazed Ibne Noor
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Contributions

Mir Akmam Noor Rashid and Wazed Ibne Noor are the graduate students involved in this project who actively carried out the experiments, characterizations, compilation, and analysis of the data. Mir Akmam Noor Rashid mostly contributed to drafting the article. Tanveer Saleh is the principal investigator of the projects who conceptualized the whole research problems. He is the main supervisor of the above students and guided them during experimentation and data analysis. Mohamed Sultan Mohamed Ali is one of the research collaborators who provided crucial technical input on the manuscript.

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Correspondence to Tanveer Saleh.

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Rashid, M.A.N., Saleh, T., Noor, W.I. et al. Effect of laser parameters on sequential laser beam micromachining and micro electro-discharge machining. Int J Adv Manuf Technol 114, 709–723 (2021). https://doi.org/10.1007/s00170-021-06908-8

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