Parametric Optimization of Nd:YAG Laser Microgrooving of Alumina Ceramic Using Integrated RSM-PSO Approach

In order to manufacture various products with well-suited quality by machining, appropriate choice of process parameters is of prime importance. Hence, the present work focuses on modeling and optimization during Nd:YAG laser microgrooving of K-60 alumina ceramic material with an objective to find the optimum process parameters settings for minimizing the upper width deviation. The experiments are performed as per Box–Behnken design of experiments (BBDOEs) with four process parameters (diode current, pulse frequency, scanning speed, and number of passes) for parametric optimization in order to control the technological response characteristic (upper width deviation) of the precision microgrooves on K-60 alumina. Analysis of variance (ANOVA), response surface methodology (RSM), and particle swarm optimization (PSO) are subsequently proposed for predictive modeling and process optimization. Result shows the optimal setting of machining variables in laser microgrooving of K-60 alumina ceramic at pulse frequency of 4.4 kHz, diode current of 17 amp, scan speed of 35 mm/s, number of passes as 12, with estimated groove upper width deviation of 0.02669 µm. The methodology described here is expected to be highly beneficial for manufacturing industries.