Process parameter optimisation of steel components laser forming using a Taguchi design of experiments approach

Abstract

The focus in this research investigation is to investigate the Process Parameter Optimisation in Laser Beam Forming (LBF) process using the 4.4 kW Nd: YAG laser system – Rofin DY 044 to form 200 x 50 x 3 mm3 mild steel - AISI 1008 samples. The laser power P, beam diameter B, scan velocity V, number of scans N, and cooling flow C were the five input parameters of interest in the investigation because of their influence in the final formed product. Taguchi Design of Experiment (DoE) was used for the selection and combination of input parameters for LBF process. The investigation was done experimentally and computationally. Laser Beam Forming (LBF) input parameters were categorised to three different levels, low (L), medium (M), and high (H) laser forming (LBF) parameters to evaluate parameters that yield maximum bending and better surface finish/quality. The conclusion drawn from LBF process is that samples which are LBFormed using low parameter settings had unnoticeable bending and good material surface finishing. On the other hand, samples LBFormed using medium parameters yielded visible bending and non-smooth surface finishing, while samples processed using high LBF parameters yielded maximum bending and more surface roughness than the other two process parameters.