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Dimensional accuracy improvement by parametric optimization in pulsed Nd:YAG laser cutting of Kevlar-29/basalt fiber-reinforced hybrid composites

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Abstract

Laser cutting proves its suitability for cutting of single fiber-reinforced polymer (FRP) composites compared with conventional cutting techniques due to reduced fiber delamination, matrix cracking and fiber pullout. However, the performance of the laser cutting process of hybrid FRP composites is yet to be revealed, which paves the way of the present study. In this article, an experimental investigation of the laser cutting process is carried out on 1.35-mm-thick Kevlar-29 and basalt fiber-reinforced polymer (KBFRP) hybrid composite laminates using 250 W pulsed Nd:YAG laser system. The performance of laser cutting was evaluated by quantifying different kerf quality characteristics such as top and bottom kerf width, top and bottom kerf deviation and kerf taper. These kerf quality characteristics define the geometrical accuracy of the laser cut. Response surface methodology-based Box–Behnken design was adopted for conducting the experiments with varied settings of laser cutting parameters, viz. lamp current, pulse width, pulse frequency, compressed air pressure and cutting speed. Second-order regression models of each response were developed and validated by using standard error plots. A parametric effect analysis was carried out by using the variation of performance measures predicted through developed mathematical models. In order to achieve the optimal levels of the process parameters for all kerf quality characteristics, a self-developed python language-coded TLBO algorithm was used. Finally, the confirmation experiments were performed at obtained optimal levels of laser cutting parameters. An overall improvement of 22.23% in multiple kerf quality characteristics was achieved through optimal settings of laser cutting parameters. The individual improvement of 11.44%, 8.47%, 17.65%, 15.22% and 58.87% was recorded in top kerf width, bottom kerf width, top kerf deviation, bottom kerf deviation and kerf taper, respectively. The developed mathematical models and suggested optimal conditions are able to provide direction to the researchers for obtaining higher-dimensional accuracy in Nd:YAG laser cutting of KBFRP hybrid composites.

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Abbreviations

b 0, b ii and b ij :

Regression coefficients

f :

Pulse frequency (Hz)

F value:

F test value

I :

Lamp current (A)

K 1, K 2, …, K 6 :

Replications of kerf width measurement

K best :

Result of the best learner for a particular subject

m :

Number of subjects

n :

Number of learners

M ij :

Mean of results for particular subject ‘j’ (j = 1, 2, 3, …, m)

p :

Compressed air pressure (kg/cm2)

P value:

Probability value

PW:

Pulse width (ms)

r i :

Random number between 0 and 1

R 2 :

Regression coefficient of determination

R 2 adj.:

Adjusted regression coefficient of determination

S :

Cutting speed (mm/min)

S value:

Standard deviation

T F :

Teaching factor in the range between 1 and 2

W 1, W 2, W 2, W 3, W 4 and W 5 :

Assigned weights for functions Z1, Z2, Z3, Z4 and Z5, respectively

x ij :

Values of laser parameters for ith observation and jth level

X j, kbest, i :

Result of the best learner in subject j

y :

Output response

Z :

Normalized combined objective function

Z 1, Z 2, Z 3, Z 4 and Z 5 :

Regression models of TKW, BKW, TKD, BKD and KT, respectively

Z 1(min), Z 2(min), Z 3(min), Z 4(min) and Z 5(min) :

Minimum values of TKW, BKW, TKD, BKD and KT, respectively

ANOVA:

Analysis of variances

BKD:

Bottom kerf deviation

BKW:

Bottom kerf width

CFRP:

Carbon fiber-reinforced polymer

DOE:

Design of experiments

FRP:

Fiber-reinforced polymer

GFRP:

Glass fiber-reinforced polymer

GRA:

Grey relational analysis

HAZ:

Heat-affected zone

KBFRP:

Kevlar-29/basalt fiber-reinforced polymer

KFRP:

Kevlar fiber-reinforced polymer

KT:

Kerf taper

LBC:

Laser beam cutting

Nd:YAG:

Neodymium-doped yttrium aluminum garnet

RSM:

Response surface methodology

TKD:

Top kerf deviation

TKW:

Top kerf width

TLBO:

Teaching–learning-based optimization algorithm

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Acknowledgements

The authors sincerely express their heartiest thanks to Dr B.N. Upadhayay, SOF, Solid State Division of RRCAT (Raja Ramanna Centre for Advanced Technology), Indore (MP), for providing the experimental support for this work. The authors are also grateful to the management of Jaypee University of Engineering and Technology, Guna (MP), India, for their laboratory and financial assistance to carry out this research work.

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  1. Department of Mechanical Engineering, Jaypee University of Engineering & Technology, P.B. No.1, A.B. Road, Guna, 473226, Madhya Pradesh, India

    Girish Dutt Gautam & Dhananjay R. Mishra

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  1. Girish Dutt Gautam
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  2. Dhananjay R. Mishra
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Correspondence to Girish Dutt Gautam.

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Gautam, G.D., Mishra, D.R. Dimensional accuracy improvement by parametric optimization in pulsed Nd:YAG laser cutting of Kevlar-29/basalt fiber-reinforced hybrid composites. J Braz. Soc. Mech. Sci. Eng. 41, 284 (2019). https://doi.org/10.1007/s40430-019-1783-y

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