Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol.

3, Issue 3, May-Jun 2013, pp.393-401

Expert modeling and multi objective optimization of laser trepan drilling of titanium alloy sheet
1
1,2,3

. Md Sarfaraz Alam*, 2 Md Tabish Haque

Motilal Nehru National Institute of Technology, Allahabad-211004, Uttar Pradesh, India

ABSTRACT
Nowadays laser machining became an attractive machining process for difficult to cut materials like ceramics, composites and super alloys. Titanium alloys specially Ti-6Al-4V (grade 5) is most widely used for different technologically advanced industries due to their superior performance characteristics such as high strength and stiffness at elevated temperatures, high strength to weight ratio, high corrosion resistance, fatigue resistance, and ability to withstand moderately high temperatures without creeping. Laser trepan drilling (LTD) being a thermal and non contact nature and having the ability to produce micro dimensions with required level of accuracy. However laser drilled holes are inherently associated with a number of defects like non circularity of hole, spatter thickness and hole taper. The present paper investigate the laser trepan drilling(LTD) process performance during trepanning of titanium alloy (Ti-6Al-4V) by modeling and simultaneous optimization of three important performance challenges such as hole taper (HT), circularity at entrance (CIRentry) and circularity at exit (CIRexit). A hybrid approach of artificial neural network (ANN)-genetic algorithm (GA) and grey relational analysis (GRA) has been proposed for multi-objective optimization. The verification results are in the close agreements with the optimization results.

1. INTRODUCTION
The laser drilling process is one of the most widely used thermal energy based noncontact type advance machining process which can be applied across a wide range of materials. Nowadays laser drilling is finding increasingly widespread application in the industries. Laser beam machining is based on the conversion of electrical energy into light energy and then into thermal energy to remove the material from work piece. The material removal process is by focusing laser beam onto the work material for melting and vaporizing the unwanted material to create a hole. CO2 laser drilling has been widely used in industries because of its high production rate and abilities on rapidly varying holes size, drilling holes at shallow angle, and drilling hard-to-work material such as high strength materials, ceramic and composite. Laser drilled holes are inherently associated with a number of defects. Non circularity of hole, spatter thickness, and hole taper are some defects associated with laser drilling. As a result, the quality of the drilled holes is the main issue in the laser drilling process. There are two types of laser drilling: trepan drilling and percussion drilling. Trepan drilling involves cutting around the circumference of the hole to be generated, whereas percussion drilling is carried out by utilizing a focused laser spot to heat, melt and vaporize the target material such that a desired hole is formed through the work piece with no relative movement of the laser or work material [1,2]. Fig. 1 shows a schematic of laser beam drilling [2]

Keywords: ANN, GA, GRA and LTD.

Fig. 1: Schematic of laser beam drilling

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A Number of researchers have performed the experimental studies to investigate into the process of laser percussion drilling by considering some significantly affecting factors/ process parameters, without applying any scientifically designed experimentation technique, further analyzing the impact of every parameter on observed process performance characteristics. Tongyu and Guoquan, [3] performed a study to investigate the relationship of laser beam parameters (energy, power, pulse width, pulse frequency) with the hole geometrical quality characteristics and to find feasibility of high carbon steel to investigate the heat affected zone in laser drilling. Laser percussion drilling of alumina ceramics was investigated by Kacar et al, [4] to determine the effect of peak power (2-11 kw) and pulse duration (0.5-7 ms) on geometrical features of drilled holes such as diameter at entrance and exit, crater (Initial cavity before getting through hole) diameter and hole taper angle. The crater diameter and the hole exit diameters shows proportional changes with the Pulse duration and peak power, although, the entrance hole diameter do not changes much with them. The reason they found, after morphological investigation with the help of optical microscope that the resolidified material at the entrance side increases with the increase in pulse duration and peak power, which ultimately reduces the entrance hole diameter even after larger crater diameter. Also due to the same reason there is a decrease in taper angle at the same conditions, which further becomes negative for higher values of process parameters. Ghoreishi et al. [5] investigated the relationships and parameter interactions between laser peak power, laser pulse width, pulse frequency, number of pulses, assist gas pressure and focal plane position on the hole taper and circularity in laser percussion drilling of stainless steel and mild steel. The central composite design was employed to plan the experiments in order to obtain required information. The process performance was evaluated in terms of equivalent entrance diameter, hole taper and hole entrance circularity. They found that the pulse frequency had a significant effect on the hole entrance diameter and hole circularity in drilling stainless steel unlike the drilling of mild steel, where the pulse frequency had no significant effect on the hole characteristics. Benyounis and Olabi [6] did a comprehensive literature review of the applications of design of experiments, evolutionary algorithms and computational networks on the optimization of different welding processes through mathematical models. According to their review of various literatures, they were of the opinion that there was considerable interest among the researchers in the adaption of response surface methodology (RSM) and artificial neural net- work (ANN) to predict responses in the welding process. For a smaller number of experimental runs, they noted that RSM was better than ANN and genetic algorithm (GA) in the case of low order non-linear behavior of the response data. In the case of highly non-linear behavior of the response data, ANN was better than other techniques. They also observed that the Taguchi approach of S/N ratio might lead to nonoptimal solutions with less flexibility and the conducting of needless experiments. Some recent attempts have been made to control the laser drilled hole taper through the development of drilling techniques [7, 8]. Ng and Li [9] assessed the effect of laser peak power and pulse width on the hole geometry repeatability in Nd:YAG laser percussion drilling of 2 mm thick mild steel sheets. Thirty-five holes were drilled and analyzed for each set of identical laser parameters. They found that higher peak power and shorter pulse width gave better hole geometry repeatability. The circularity of the entrance hole ranged from 0.94 to 0.87, and was found to correlate with repeatability. Titanium and its alloys are most widely used for different technologically advanced industries such as aerospace, marine, chemical, food processing and medical due to their superior performance characteristics such as high strength and stiffness at elevated temperatures, high strength to weight ratio, high corrosion resistance, fatigue resistance, and ability to withstand moderately high temperatures without creeping [10]. The Ti-6Al-4V is an alloy (grade 5) of Ti, has extensively used in aerospace, marine, chemical processing, medical and automobile sectors for making different components such as airframes, fastener components, vessels, cases, hubs, forgings, bone plates, rods, expendable ribs cages, finger and toe replacements, spinal fusion cages and dental implants, pistons and piston rings. Ti and its alloys cannot be cut easily by conventional cutting methods due to their improved mechanical properties, poor thermal conductivity, low elastic modulus and high chemical affinity at elevated temperatures. Due to the poor thermal conductivity of these alloys, the heat generated during the cutting cannot dissipated properly which results very high temperature at the toolwork piece interface and melting of the tool tip. Thus adversely affects the tool life. Ti is chemically reactive at elevated temperatures due to which the tool material either rapidly dissolves or chemically reacts during the cutting process, resulting premature tool life [11]. The low elastic modulus of Ti alloys permits greater deflection of workpiece during machining and complexity of the machining increases. While machining the Ti alloys, the contact length between the tool and chip has been found very small due to which high cutting temperatures and high cutting stresses are concentrated near the tool tip which results the melting of tool tip and finally tool life reduces. Due to the thermal plastic instability, the shear strains in

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the chips are not uniform which promotes the formation of serrated chips. These serrated chips create fluctuations in the cutting force (generates vibrational forces) which are responsible for sever flank wear of cutting tools [12]. Thus there is a crucial need for reliable and effective cutting process for Ti and its alloys. Alternatively for the cutting of these materials advanced cutting processes such as Electric discharge machining, ultrasonic machining, laser beam machining may be used with some limitations. But for using these advanced cutting methods, a lot of research work has been required so that the required objectives may be fulfilled by controlling different process parameters. Most of the previous works related to hole drilling used the percussion drilling process where with intense laser burst, the hole size was the size of the beam that was varied by focusing. The present study focuses on the alternative trepan drilling. This paper reports the multi-objective optimization of hole geometrical qualities such as HT, CIRentry and CIRexit in the pulsed Nd:YAG laser trepanning of Titanium alloy sheet. The motivation for the investigation is the fact that Titanium alloys being increasingly used in different industries and engineers of these industries are trying to obtain best qualities of these materials in the laser drilling. In this investigation, Ti-6Al-4V (Titanium alloy sheet grade 5) sheet has been selected because it is known for its exceptional performance characteristics and is one of the mostly used Titanium alloys. Due to higher material costs, the Ti alloys require such type of drilling methods in which minimum wastage of materials is obtained with satisfactory trepanned qualities. But the reported research works show that poor qualities are obtained by use of air or nitrogen assist gases due to low thermal conductivity and high chemical reactivity at elevated temperatures. The use of costlier inert gases may further increase the cutting cost. Therefore, the aim of present research is to obtain good quality of trepanned hole by using N 2 as assist gas. ANN has been applied for the modeling of HT, CIRentry and CIRexit with the help of data obtained by the L27 orthogonal array experimentation. The hybrid approach of ANN, GA and GRA based entropy measurement technique has been applied for modeling and multi-objective optimization of HT, CIRentry and CIRexit. The predicted optimum results have been verified by confirmation tests. throughout the experiments. The focal length of the lens is 50 mm and the standoff distance is 1 mm. The Titanium alloy sheet (Ti-6Al-4V) of thickness 1.4 mm is used as work material. The chemical compositions of the Ti-6Al-4V are shown in Table 1. Pulse width or pulse duration, pulse frequency, assist gas pressure and cutting speed have been selected as input process parameters (control factors). An exhaustive pilot experimentation has been performed in order to decide the range of each control factors for complete through cutting. The different control factors and their levels are shown in Table 2. The quality characteristics or responses selected for the analyses are HT, CIRentry and CIRexit. 1 mm diameter holes are made with two repetitions for the each experimental run. The hole diameters at the entrance and exit were measured at six orientations at an interval of 300. Diameters are measured by using optical microscope with 10X magnification supplied by Radical instruments, India. The HT, CIRentry and CIRexit were calculated by following formula: Hole taper

f entrance

d f exit

(Since =tan , for small value of ) Where (df) entrance and (df) exit are mean Ferets diameters at the entrance and exit, respectively and (t) is the drilled hole depth.

Circularity at entry/exit

2. EXPERIMENTAL SETUP AND DESIGN OF E XPERIMENTS

The experiments have been performed on 200W pulsed Nd:YAG laser cutting system with CNC work table supplied by SIL Pune, India. The assist gas used is Nitrogen and it is passed through a nozzle of 1 mm diameter, which remains constant

where (df) Min and (df) Max are minimum and maximum Ferets diameters at entrance or exit side of drilled hole. The total number of experiments can be substantially reduced with the help of a well designed experimental plan without affecting the accuracy during the experimental study of any manufacturing process. Taguchi have suggested that it is better to make the process robust rather than equipments and machinery just by nullifying the effects of variations through selection of appropriate parameter level. Taguchi has suggested properly designed experimental matrices known as orthogonal arrays (OAs) to conducts the experiments. In this present research work four control factors with three levels of each have been considered. Hence experiments can be performed

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by using simplest L9 OA. But authors have selected L27 OA Table 1: Composition of titanium alloy sheet (grade-5) (% volume) Al 6.22 Fe 0.187 Sn 0.56 for high resolution Ti 89.6 factor [13].

V 3.35

Table 2: Control factors and their levels Symbol X1 X2 X3 X4 Factors Pulse width (ms) Pulse frequency (Hz) Gas pressure (kg/cm2) Trepanning speed (mm/s) Level 1 0.8 13 6 0.1 Level 2 1.2 17 8 0.2 Level 3 1.6 21 10 0.3

3. METHODOLOGY
3.1. ARTIFICIAL NEURAL NETWORK (ANN) ANN is information processing paradigm inspired by biological nervous systems like our brain. In neural network a large number of highly interconnected processing elements (neurons) are working together. Like people, they learn from experience. In a biological system, learning involves adjustments to the synaptic connections between neurons; the same is true for ANNs [14]. In the network, each neuron receives total input from all of the neurons in the preceding layer as (1) Where the total or net input and N is are the numbers of inputs to the rth neuron in the forward layer. is the weight of the connection to the qth neuron in the forward layer from the r th neuron in the preceding layer , is the input from the rth neuron in the preceding layer to the forward layer and the bias to qth neuron . A neuron in the network produces its output ( ) by processing the net input through an activation function , such as log sigmoid function and pure linear function chosen in this study as below (2) & (3) In calculation of connection weights, often known as network training, the weights are given quasi-random initial values. They are then iteratively updated until converges to the certain value using the gradient descent method. Gradient descent method updates weights so as to minimize the mean square error between the network output and the training data set. For simultaneous optimization of more than one quality characteristics, sometimes it is desirable to normalize the quality characteristics. So the training data set, i.e. the experimental values of

quality characteristics have been normalized using following formula: (4) Where the normalized value of the kth response is during ith observation, is the maximum value of for the kth response. 3.2. GENETIC
ALGORITHM OPTIMIZATION

(GA)

FOR

Genetic algorithms (GA) are the global optimization technique which is quite suitable for non-linear optimization problems. GA is based on the Darwins principle of survival of fittest .The algorithm starts with the creation of random population. The individual with best fitness are selected to form the mating pair and then the new population is created through the process of crossover and mutation. The new individuals are again tested for their fitness and this cycle is repeated until some termination criteria are satisfied [14]. 3.3 GREY RELATIONAL ANALYSIS (GRA) A common difficulty with multi-objective optimization is the appearance of an objective conflict; none of the feasible solution allows simultaneous optimal solution for all objectives. The individual optimal solutions of each objective are usually different. To get the solution of multiobjective optimization problem, using classical methods, all the objectives are converted into single objective function. There are many methods of transforming multi-objective optimization problem into single objective optimization problem and objective weighting method is one of the popular methods. In objective weighting method, multi-objective functions are combined into one overall objective function by assigning different weigh to different objective [15]. The determination of weight is a critical aspect, which sometimes is decided by designers experience or some mathematical techniques. In this study, the GRA coupled with entropy measurement technique [16] has been used to find the weight of each quality characteristics for multi-objective

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optimization. The working of the GRA and entropy measurement technique has been explained with the help of block diagram in Fig. 2.
Normalization of data Calculation of grey relational coefficient Calculation of the sum of the grey relational coefficient Evaluation of the normalized coefficient

Calculation of the weight of each quality characteristic

Calculation of the sum of entropy

Calculation of the entropy of each quality characteristics

Fig. 2: Block diagram for GRA and Entropy measurement technique The normalized value of the quality characteristics have been calculated using Eqs. (4), and have been shown in the Fig.3. 1.2 Normalized values 1 0.8 0.6 0.4 0.2 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 Experiment Number Fig. 3: Normalized values of quality characteristics Hidden layer Experimental values for NHT Experimental values for NCIRentry Experimental values for NCIRexit

4. MODELING
The optimal neural network architecture used for normalized hole taper (NHT), normalized circularity at entry (NCIRentry) and normalized circularity at exit (NCIRexit) is shown in Fig. 4. The network for all three NHT, NCIRentry and NCIRexit consists of one input, one hidden and one output layer. The input and output layers have four and one neuron respectively. The neurons in input layer are corresponded to Pulse width, Pulse frequency, Gas pressure and Trepanning speed. Output layer corresponds to NHT, NCIRentry and NCIRexit. The hidden layer has five neurons in case of all. The activation function used for the hidden layer and output layer was log sigmoid and pure linear respectively. In this work, a commercially available software package MATLAB was used for the training of ANN .The values of the weights, and biases, after network getting fully trained are shown in the Table 3 for all the NHT, NCIRentry and NCIRexit. X1

Input layer

Output layer

X2
NHT/ NCIRentry/ NCIRexit

X3

X4

wqr

bq

Fig. 4: Architecture of artificial neural network for NHT, NCIRentry and NCIRexit

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Table 3: Final values of Weights and Biases for NHT, NCIRentry and NCIRexit Weights to hidden layer from input layer NHT [122.7035 -28.3073 16.9694 33.6773; -4.8487 -22.6453 -32.7136 10.3398; 2.8113 -2.9929 5.8978 0.53677; 3.9119 3.3126 0.68229 0.29932; -2.7571 2.4243 -5.7577 -0.61036] [-3.0176 -4.1509 60.4266 0.77578; 1.0815 6.3481 1.2684 1.7164; -1.1774 -6.0712 -1.3746 -1.6547; 41.2793 -1.1825 8.5567 -34.2151; 5.5617 -56.9911 1.8769 2.2187] [19.7725 6.0393 -7.3166 -1.7965; 0.26041 67.3029 -70.1356 78.0474; -45.1386 185.994 64.4417 66.0488; -57.4946 0.24336 0.11946 0.53196; 20.0861 -59.1983 24.6627 61.9418] Bias to hidden layer [81.9011; 58.7437; -1.1352; -4.0345; 0.56399] [29.6378; -8.1871; 8.1269; -3.1741; 51.2141] [-13.606; -9.8892; -225.056; 64.2284; 64.7269] Bias to output layer -2.3246 [46.4105 ]

Weights to output layer [0.33548 -0.44801 105.1382] -43.5783

NCIRentry

[-0.094972 0.074669]

-4.8731

-5.0107

-0.046963

[6.129]

NCIRexit

[-0.074678 0.047406 -0.045112 -66.1898 0.048632]

[67.1431 ]

So, in the mathematical form, the ANN model for NMRR can be represented as follows: NHT/NCIRentry/NCIRexit (5) Where and corresponded to weight and bias to output layer and is the net input to the output layer from hidden layer and it is given by,

The values of

, ,

and

q=1, 2 5 are shown in Table 3.

The results of the experimental data and neural network predicted data for NHT, NCIRentry and NCIRexit have been compared in the Table 4. It is evident that ANN prediction is in good agreement with the experimental results. It is found that ANN with mean square error of 0.000037%, 0.0000186% and 0.000125% respectively, appears to constitute a workable model for predicting the characteristics under given set of input parameters for LTD.

I: Experiment No. V: Trepanning speed Experimental Circularity

II: Pulse width III: Pulse frequency IV: Gas pressure VI: Experimental Hole taper VII: Experimental Circularity VIII: at entry at exit

IX: ANN predicted Hole taper in prediction of

X: ANN predicted Circularity

XI: ANN predicted Circularity XII: % error

at entry at exit Hole taper XIII: % error in prediction of XIV: % error in prediction of Circularity at entry Circularity at exit Table 4: Comparison of ANN predicted result with the experimental result for NHT, NCIR entry and NCIRexit I II III IV V VI VII VIII IX X XI XII XIII 1 2 3 4 5 0.500 0.500 0.500 0.500 0.500 0.619 0.619 0.619 0.810 0.810 0.600 0.800 1.000 0.600 0.800 0.333 0.667 1.000 0.667 1.000 0.433 0.736 0.992 0.539 0.691 0.914 0.927 0.973 0.902 0.910 0.966 0.942 0.963 0.970 0.955 0.433 0.736 0.991 0.539 0.691 0.914 0.927 0.973 0.902 0.910 0.952 0.952 0.961 0.971 0.955 0.055 0.051 0.027 0.079 0.049 0.005 0.005 0.004 0.003 0.004

XIV 1.468 1.096 0.150 0.100 0.033

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6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0.500 0.500 0.500 0.500 0.750 0.750 0.750 0.750 0.750 0.750 0.750 0.750 0.750 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.810 1.000 1.000 1.000 0.619 0.619 0.619 0.810 0.810 0.810 1.000 1.000 1.000 0.619 0.619 0.619 0.810 0.810 0.810 1.000 1.000 1.000 1.000 0.600 0.800 1.000 0.600 0.800 1.000 0.600 0.800 1.000 0.600 0.800 1.000 0.600 0.800 1.000 0.600 0.800 1.000 0.600 0.800 1.000 0.333 1.000 0.333 0.667 0.667 1.000 0.333 1.000 0.333 0.667 0.333 0.667 1.000 1.000 0.333 0.667 0.333 0.667 1.000 0.667 1.000 0.333 0.584 1.000 0.703 0.900 0.337 0.372 0.437 0.437 0.293 0.670 0.555 0.696 0.668 0.335 0.517 0.710 0.513 0.526 0.834 0.656 0.664 0.914 0.914 0.971 0.902 0.942 0.935 0.956 0.957 0.952 0.919 0.944 0.937 0.925 0.985 0.974 0.961 1.000 0.969 0.946 0.980 0.991 0.970 0.977 0.935 0.954 0.904 0.942 0.927 0.960 0.901 0.962 0.919 0.921 0.884 0.902 0.946 1.000 0.947 0.979 0.949 0.960 0.967 0.986 0.978 0.904 0.584 1.000 0.704 0.899 0.338 0.371 0.437 0.436 0.292 0.670 0.555 0.696 0.669 0.335 0.518 0.710 0.514 0.526 0.834 0.656 0.665 0.913 0.914 0.971 0.902 0.942 0.935 0.956 0.958 0.952 0.918 0.943 0.937 0.925 0.985 0.974 0.960 1.000 0.969 0.947 0.980 0.991 0.971 0.977 0.935 0.954 0.906 0.943 0.926 0.961 0.901 0.964 0.921 0.922 0.884 0.901 0.945 0.999 0.947 0.978 0.949 0.962 0.968 0.986 0.977 0.903 0.001 0.000 0.038 0.043 0.015 0.116 0.002 0.181 0.398 0.067 0.038 0.011 0.165 0.009 0.179 0.021 0.222 0.093 0.006 0.007 0.107 0.186 0.095 0.002 0.001 0.003 0.003 0.000 0.069 0.006 0.113 0.110 0.002 0.002 0.001 0.006 0.061 0.000 0.002 0.124 0.010 0.000 0.009 0.003 0.004 0.043 0.201 0.055 0.132 0.121 0.001 0.117 0.176 0.120 0.003 0.160 0.105 0.090 0.001 0.094 0.049 0.267 0.100 0.015 0.069 0.152

5. MULTI OBJECTIVE OPTIMIZATION

Using GRA coupled with entropy measurement, the weight for NHT, NCIRentry and NCIRexit have been found as 0.33, 0.33 and 0.34 respectively. Now the multi-objective optimization problem can be transformed into single objective optimization problem. In the present case, both the objective functions are of conflicting nature because the aim is to maximize HT the and minimize the NCIRentry, NCIRexit. Thus, the objective function of optimization problem can be stated as below: Find: X1, X2, X3 and X4 Minimize:

Where = 0.33, 0.33 and = 0.34 NHT, NCIRentry and NCIRexit Eq. (5) ,with range of process input parameters: 0.8 1.6 13 21 6 10 0.1 0.3 The critical parameters of GA are the size of the population, cross-over rate, mutation rate, and number of generations. After trying different combinations of GA parameters, the population size 20, cross-over rate 0.8, mutation rate 0.01 and number of generation 40, have been taken in the present study. The objective function in Eq. (6) has been solved without any constraint. The generation-fitness graphics have been shown in the Fig.5. The fitness function is optimized when the mean curve converges to the best curve after 7 generation. The corresponding values of Pulse width, Pulse frequency, Gas pressure and Trepanning speed have been found as1.3 ms, 17 Hz, 8 kg/cm2 and 0.2 mm/s.

(6)

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Fig. 5: The generation-fitness graphics

6. DISCUSSION
Achieving a good compromise between objective functions in multi-objective optimization problem is a big challenge due to existence of multiple solutions, known as Pareto-optimal solutions. To overcome it, in the present work, weights for each quality characteristics have been calculated first, to get optimal solution.

[2]

[3]

7. CONCLUSIONS
The multi-objective optimization of laser trepan drilling of Ti-6Al-4V using hybrid approach of artificial neural network, genetic algorithm and grey relational analysis with entropy measurement technique has been done. Following conclusions have been drawn on the basis of results obtained: (1) The developed models for HT, CIRentry and CIRexit, with mean square error of 0.000037%, 0.0000186% and 0.000125% respectively, are well in agreement with the experimental result. (2) The optimum levels of control factors are Pulse width, Pulse frequency, Gas pressure and Trepanning speed have been found as 1.3 ms, 17 Hz, 8 kg/cm2 and 0.2 mm/s respectively. (3) Validation has been performed in order to verify the result, which shows a good agreement between the optimized and experimental result. [4]

[5]

[6]

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