Nonconventional Technologies Review no.

4/2011

EXPERIMENTAL INVESTIGATIONS OF CO2 LASER CUT QUALITY: A REVIEW Miroslav RADOVANOVIC, Milos MADIC
University of Nis, Faculty of Mechanical Engineering in Nis, Serbia

Abstract
Laser cutting is one of the most widely used thermal energy based non-contact type advance machining process. In recent years, considerable experimental investigations have been carried out aiming at improving laser cutting process performance. This review paper aims at presenting the state of the art in the field of CO2 laser cutting of various engineering materials with special emphasis on experimental investigations that dealt with analyzing process parameters that affect the cut quality characteristics. In addition it reports about the most used types of experimental plans used.

Keywords: CO2 laser, laser cutting, cut quality, experiment, review 1. INTRODUCTION Emergence of advanced engineering materials, stringent design requirements, intricate shape and unusual size of workpiece restrict the use of conventional machining methods [1]. Among various advanced machining processes laser beam machining (LBM) is one of the most widespread applications of lasers and a well-established and effective method of cutting a wide range of materials, mainly metals [28]. LBM has several advantages over conventional methods. Firstly, as non-contact process, LBM it well suited for cutting advanced engineering materials such as difficult to cut materials, brittle materials, electric and nonelectric conductors, and soft and thin materials [19]. Secondly, LBM is a thermal process and materials with favorable thermal properties can be successfully processed regardless of their mechanical properties. Thirdly, LBM is a flexible process [24]. Other advantages include narrow kerf width (minimum material lost), straight cut edges, low roughness of cut surfaces, minimum metallurgical and surface distortions, easy integration with computer numerically controlled (CNC) machines for cutting complex profiles [30]. Sheet-metal cutting is the single largest, in terms of sales, global industrial laser application. CO2 lasers dominate this application due to their good-quality beam combined to high output power [26]. It is estimated that more than 40,000 cutting machines using CO2 lasers have been installed worldwide [54]. The laser cutting is one of the largest applications of lasers in metal working industry. It is based on the precise plate cutting by focused laser beam. Laser beam is a new universal cutting tool able to cut almost all known materials. With respect to various other cutting processes (such as oxy-fuel cutting, plasma cutting, sawing and punching), its advantages are numerous, namely, a narrow cut, minimal area subjected to heat, a proper cut profile, smooth and flat edges, minimal deformation of a workpiece, the possibility of applying high cutting speed, intricate profile manufacture and fast adaptation to changes in manufacturing programs. For most engineering applications, the laser can be regarded as a device for producing a finely controllable energy beam, which, in contact with a material, generates considerable heat. The heat energy is supplied by a laser beam. The laser beam permits tool-free machining with active heat energy. The energy of light contained in the laser radiation is absorbed by the workpiece and transformed into thermal energy. Laser beam is becoming a very important engineering tool for cutting. Laser cutting, especially of mild steel, is rather well introduced than new attractive process for thin sheet cutting. It is one of the most important applications for industrial lasers. Laser cutting is one of the important applications of LBM. It finds wide application in various manufacturing industries due to its high speed, quick setup, low waste, precision of operation and low cost [8, 19, 36]. A market survey by Anderson [53] estimates the total LBM systems market to be worth

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over $1 billion per annum, of which laser cutting, is the second largest market behind laser marking. Laser cutting is thermal, non-contact, mechanized process capable of cutting most materials with a high degree of precision and accuracy. Laser cutting is the process of melting or vaporizing material in a very small, well defined area. Processes of heating, melting, and evaporation are produced by the laser beam affecting a workpiece surface.

the machine providing motion, in addition to the applied numerically controlled system, it is possible to provide for a continual sheet cutting along the predetermined contour. For many potential users of laser cutting technology, it was strategically important to invest in future technology. The high investment and operating costs for laser cutting technology, compared to conventional cutting technologies, must be justified according to economic criteria with corresponding technical and financial advantages.

Fig.1. Laser cutting A laser beam is a high intensity beam of light that can be tightly focused onto a spot only 0.10.2 mm in diameter. Energy of laser beam is focused to a small spot diameter to achieve the necessary power density. For best results, steel typically requires a power density of 107 do 108 W/cm2. There is no other way to concentrate so much energy into such a small spot. The high power density of the focused laser beam in the spot melts or evaporates material in a fraction of a second. Since our desire is to remove the evaporated and molten material from the affected zone as soon as possible, the laser cutting is performed with a coaxial current of the assist gas gas assist laser cutting, Figure 1. In cutting of metals, gas, such as nitrogen, air or oxygen, assist laser cutting is normally applied. In gas assisted laser cutting, the gas is usually introduced coaxially with the focused laser beam into the cutting area. The gas cools the cut area, thus lowering the heat affected zone, and also removes molten dross from the cut. A desired cut is obtained by moving the laser beam along a given contour. By combining the laser beam and

Fig.2. Laser cut Laser cutting is the high speed cutting with a narrow kerf that results in superior and enhanced quality, higher accuracy and greater flexibility. It is often wondered what type of cut edge finish is generated by laser cutting. Each cut of conventional cutting processes provides a consistent, known degree of quality which can serve as a reference for subjectively comparing results. Laser cut can be said to fall somewhere between a sawed edge and that of an EDM cut. In Figure 2 is shown laser cut. The cut quality refers to the cut geometry, the cut surface quality and physical and chemical characteristics of the material in the surface cut layer. The standard DIN EN ISO 9013:2000 gives describes criteria for evaluating the quality of cutting surfaces, quality classification and the dimensional tolerance. Evaluation of laser cut quality bases on: geometry of cut, surface of cut, burr formation and characteristics of material in zone of cut. The cut geometry comprises the following: kerf (kerf profile and kerf width), perpendicularity and slant tolerance, and

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rounding out of the cut edges. Kerf is important characteristic of laser cutting that ensures the advantage in regard to other contour cutting processes. Kerf profile by laser cutting has form of taper. The channel effect of a focused beam minimizes taper of the kerf. Kerf width increases along with the sheet thickness and with increase of laser power. By cutting with laser power of 800 W kerf width is 0.2 mm for sheet thickness of 1 mm, 0.25 mm for 3 mm, and 0.3 for 6 mm. The perpendicularity and slant tolerance also determine the cut quality. The cutting of material by means of the focused laser beam is characterized by narrowing of the cut. Its size depends on many factors, primarily on the focal length of the focusing lenses as well as on position of focal point, in addition to the properties of the workpiece material and the laser beams polarization. In order to determine quantitatively the perpendicularity the slant tolerance and the cut sides' inclination angle are used. The perpendicularity and slant tolerance is the distance between two parallel straight lines between which the cutting surface profile must lie at the theoretically correct angle i.e. at 90 in the case of perpendicular cuts. Cut side's inclination angle increases along with the sheet thickness, but decreases with increase of laser power. By cutting with laser power of 800 W cut side's inclination angle is less than 1 for sheet thickness of 1 mm, 1.5 for 3mm, and 3 for 6 mm. The cut edges at the laser beam entrance side are rounded out due to the Gauss distribution of radiation intensity over the laser beam cross-section. The edges rounding-out is very small. The cut edge rounding radius ranges from 0.5 mm to 0.2 mm with steel sheets cutting. Cut edges rounding increases along with the sheet thickness, but decreases with increase of laser power. By cutting with laser power of 800 W cut edges rounding is 0.05 mm for sheet thickness of 1 mm, 0.12 mm for 3 mm, and 0.18 for 6 mm. 2. INVESTIGATIONS OF CO2 LASER CUT QUALITY Considerable research studies have been carried out to examine laser cutting process. The state of the art in the field of LBM of structural ceramics was reported in review paper by Samant and Dahotre [55]. The state and future prospect of the art of industrial

lasers used for fine cutting of metal plates is discussed by Tabata et al. [56]. Comprehensive review papers of LBM are available [1, 57, 58]. According to Dubey and Yadava [1] the research work carried out in the area of laser machining can be divided in three parts namely experimental studies, modeling studies and optimization studies. This paper reviews research work on the experimental studies of laser cutting of various engineering materials. Due to the large number of publications in the area of laser machining, the paper is restricted to the CO2 laser cutting. The quality of laser cuts is of the utmost importance in laser processing [37]. Therefore, this paper is focused on reviewing the experimental investigation concerned with analysis on effects of laser input process parameters on cut quality. An attempt has been made to review the most frequently selected laser process parameters which influences on cut quality was observed. The accuracy of experimentation can be increased by using the scientific experimental design techniques. Design of experiments (DoE) approach is superior from unplanned approach because it is a systematic and scientific way of planning the experiments, collection and analysis of data with limited use of available resources [1]. In engineering applications, among the various DoE (factorial, fractional factorial, central composite design, Placket-Burmann etc.) the Taguchi method is the most widely used experimental design technique [2]. Therefore particular attention was made whether and which type of DoE approach was implemented by researchers. The selection of the papers dealing with mentioned issues was limited to papers in SCI (Science Citation Index) listed journals published in last 15 years. Altogether, 48 papers dealing were selected and briefly presented. 3. LITERATURE REVIEW ANALYSIS AND DISCUSSION From the literature review, it is clear that a number of experimental investigations in laser cutting have been carried out. Figure 3 depicts their chronological distribution. The Figure 3 shows that experimental investigation of laser cutting of various materials has attracted a sustained interest from researchers. In fact, from 2005 till present, there was an increase in the number

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of papers published on the subject. The most papers were published in 2008 and there is a possibility that this will happen in 2011 (the survey was conducted during the first quarter of 2011).

two input process parameters, on cut quality was analyzed, Figure 5. The influence of laser power, cutting speed and gas pressure in laser materials processing was mostly analyzed. The influences of other process parameters such as nozzle type [6], flow of assist gas [17, 19], gas composition [20], laser spot size [46], and others were also examined.

Fig.3. Yearly distribution of reviewed publications Table 1 synthesizes distinct laser process parameters taken by authors along reviewed papers. The table shows considered (input) laser process parameters in each paper as well as the cut quality characteristics (output) examined. In addition to that, information is provided on the workpiece material used. According to the classification of engineering materials by Ashby [52], laser cutting of metals is mostly investigated as shown in Figure 4.

Fig.5. Number of process parameters considered in reviewed papers Laser cutting, as multi-input and multi-output process, is affected by many process parameters and their interactions. The laser cutting quality is strongly determined by the laser cutting parameters. Based on the reviewed experimental results one can see that the effect of input process parameters on cut quality r varying in different operating ranges. Therefore, there is a need for developing models (analytical, numerical, empirical, etc.) for different range of operating parameters so that prediction and optimization laser cutting would be achieved. In 54 % of the reviewed papers the authors have determined optimal cutting parameters settings for cutting the given material. This was through simple analysis of the experimental results or by using statistical and regression analysis (RA). It should be noted here that surprisingly there is no application of artificial neural networks (ANN) which have been proven as more powerful modeling technique compared to RA for investigating the correlations between process parameters in cutting processes. Integration of empirical models based on RA or ANN with modern optimization methods like genetic algorithms, simulated annealing, and particle swarm optimization provides an efficient way for modeling and optimization of laser cutting.

Fig.4. Most investigated materials for assessing laser cut quality Most papers reviewed in the literature considered one, two and three characteristics of the laser cut surface to describe the cut quality, Figure 5. Kerf width, surface roughness and heat affected zone (HAZ) were most used to assess laser cut quality. Also it should be noted that authors also used some specific quality characteristics such as waviness and flatness [41] and dimensional accuracy [8]. The quality of laser cutting of ceramic tiles was assessed in terms of crack formation (damage) [5, 46]. On the other hand, the influence of mostly, four, three and

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Table 1. CO2 laser cutting experimental investigations taken along reviewed papers
Reference
[3] [4, 5] [6] [7] [8] [9] [19] [20, 21] [10] [11] [12] [13] [14] [15, 16] [17] [18] [22] [23] [24] [25] [26, 27] [28] [29] [30] [31] [32] [33] [34]

Workpiece material
alumina alumina slate mild steel st37 steel polymers polymer mild steel composite eng. wood HSLA steel GA260 steel polymer polymer polymer AHSS steel mild steel eng. wood zinc-alume,-anneal 4130 steel aluminumcopper glass aluminum titanium mild steel aluminum mild steel

LP

CS

GP

GT

Input parameters ND FP LCM LPF WT

DT

Output parameters SR HAZ SF DF

[35] galvabond [36,37,38,39] mild steel [40] kevlar [41] Incoloy 800HT [42] stainless steel [43] plastic,wood,rubber [44] Incoloy 800 [45] alumina
galvabond [46] [47] [48] [49] alumina alumina W1.2311/12 steel Al composite

[50] steel, aluminum Were are: LP-laser power; CS-cutting speed; ND-nozzle distance; GP-gas pressure; GT-gas type; FP-focus position; LCM-laser cutting mode; LPF-laser pulse frequency; WT-workpiece thickness; DT-duty cycle; O-other, K-kerf; SR-surface roughness; HAZ-heat affected zone; SF-striation formation; DF-dross formation;

Optimization of multiple quality characteristics also have been solved such as in reference [8, 19, 11]. However, it should be noted that there is a place for implementing and other methods, keeping in mind that only two

methods were applied, namely grey relational analysis and desirability approach. Further analysis can be towards whether the experimental investigations of the influences of the input process parameters on cut quality

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were performed with a DoE approach. Figure 6 shows whether and how many types of DoE designs were used for experiment planning.

4. CONCLUSIONS This paper presents an overview of recent experimental investigations in laser cutting of various engineering materials concerned with cut quality analysis. The objective was to identify the most common process parameters analyzed, cut quality characteristics and to investigate whether and which DOE design was adopted. Researchers have contributed by investigating laser cutting process of various materials, mainly metals. The review shows that cutting conditions (laser power, cutting speed, feed, and gas pressure) are by far the most employed for studying the cut quality. On the other hand, the most of the cut quality characteristics discussed include kerf width, surface roughness, HAZ and dross formation. To this aim, most of the experimental studies have been performed without using DOE approach. Surprisingly, only few researchers adopted Taguchi experimental design. In about half of the reviewed papers the optimal cutting parameters settings for cutting the given material was determined. For optimization purpose statistical and regression analysis were used as well as Taguchi optimization method. Experiment planning according to the Taguchi method so that wider experimental range is covered and empirical data modeling by means of artificial neural networks provides an efficient approach for accurate modeling of laser cutting process. By coupling these models with optimization methods can find optimal cutting parameter settings for satisfying response characteristics in an effective way.
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Fig.6. Types of design used in experimental investigations It is clear that most of the experiments have been performed without using DoE approach or it was not clearly indicated. Altogether, the DoE approach was applied by 60 % of the authors in experimentation. Unlike, onefactor-at-a-time experimentation, the DoE based studies can be used for investigating the interaction effects among various process parameters. The very low usage of Taguchis design (8%) is surprising since it provides an efficient plan to study the entire experimental region of interest for the experimenter, with the minimum number of trials as compared with the classical DoE, especially with a full factorial design. After the analysis of the DoE design type one needs to provide information about conducted experiment trials in reviewed experimental investigations. There were studies with small and huge number of experiment trials, as shown in Figure 7. Also it should be noted that generally unreplicated designs were used.

Fig.7. Number of experiment trials

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