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Mahmoud Moradi

Mahmoud Moradi

Academic rank: Associate Professor
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Education: PhD.
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Faculty: Technical Engineering
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Research

Title
Investigation on the effects of process parameters on laser percussion drilling using finite element methodology; statistical modelling and optimization
Type
JournalPaper
Keywords
Laser Drilling, Simulation, Finite Element Method, Response Surface Method (RSM)
Year
2017
Journal Latin American Journal of Solids and Structures
DOI
Researchers Mahmoud Moradi

Abstract

In the present research, the simulation of the Nickel-base supera-lloy Inconel 718 fiber-laser drilling process with the thickness of 1mm is investigated through the Finite Element Method. In order to specify the appropriate Gaussian distribution of laser beam, the results of an experimental research on glass laser drilling were simulated using three types of Gaussian distribution. The DFLUX subroutine was used to implement the laser heat sources of the models using the Fortran language. After the appropriate Gaus-sian distribution was chosen, the model was validated with the experimental results of the Nickel-base superalloy Inconel 718 laser drilling process. The negligible error percentage among the expe-rimental and simulation results demonstrates the high accuracy of this model. The experiments were performed based on the Res-ponse Surface Methodology (RSM) as a statistical design of expe-riment (DOE) approach to investigate the influence of process parameters on the responses, obtaining the mathematical regres-sions and predicting the new results. Four parameters i.e. laser pulse frequency (150 to 550 Hz), laser power (200 to 500 watts), laser focal plane position (-0.5 to +0.5 mm) and the duty cycle (30 to 70%) were considered to be the input variables in 5 levels and four external parameters i.e. the hole's entrance and exit diame-ters, hole taper angle and the weight of mass removed from the hole, were observed to be the process output responses of this central composite design. By performing the statistical analysis, the input and output parameters were found to have a direct relation with each other. By an increase in each of the input va-riables, the entrance and exit hole diameters, the hole taper angel, and the weight of mass removed from the hole increase. Finally, the results of the conducted simulations and statistical analyses having been used, the laser drilling process was optimized by means of the desire ability approach. Good agreement between