International Journal of Machine Tools & Manufacture 46 (2006) 13011310

Modelling and analysis of pulsed Nd:YAG laser machining

characteristics during micro-drilling of zirconia (ZrO
2
)
A.S. Kuar, B. Doloi, B. Bhattacharyya

Production Engineering Department, Jadavpur University, Kolkata 700 032, India

Received 16 June 2005; received in revised form 11 October 2005; accepted 21 October 2005
Available online 5 December 2005
Abstract
Pulsed Nd: YAG laser beam has great ability for micro-machining of ceramic materials because of high laser beam intensity at low
mean beam power, good focusing characteristics due to very small pulse duration, small kerf widths and narrow heat effected zones. In
the paper, experimental investigations into CNC pulsed Nd:YAG laser micro-drilling of zirconium oxide (ZrO
2
) have been carried out.
Inuence of laser machining parameters on the HAZ thickness and phenomena of tapering of the machined micro-holes has been
experimentally investigated. Response Surface Methodology-based optimal parametric analysis has been performed to determine the
optimal setting of process parameters such as pulse frequency and pulse width, lamp current, assist air pressure for achieving minimum
HAZ thickness and taper of the micro-hole machined by pulsed Nd:YAG laser. Minimum HAZ thickness has been obtained as
0.0675 mm when the lamp current, pulse frequency, assisted air pressure and pulse width are set at optimal parametric setting i.e. 17 amp,
2.0 kHz, 2.0 kg/cm
2
and 2% of the duty cycle, respectively. Minimum taper has been achieved as 0.0319 at optimal parametric setting i.e.
the lamp current of 17 amp, pulse frequency of 2.0 kHz, assisted air pressure of 0.6 kg/cm
2
and pulse width of 2% of the duty cycle.
Analysis has also been carried out for multi-optimisation of both the responses i.e. HAZ thickness and taper during pulsed Nd:YAG
laser micro-drilling on ZrO
2
.
r 2005 Elsevier Ltd. All rights reserved.
Keywords: Laser micro-drilling; Zirconia; HAZ thickness; Taper; RSM
1. Introduction
Increasing demand for advanced difcult-to-process
materials and the availability of high-power lasers have
stimulated interest in research and development related to
laser machining. Basic material removal mechanism
involved in laser beam machining is dependent upon the
generation of high heat ux that causes melting and
vapourisation of the material where the beam is focused.
Increasing interest in the use of lasers for manufacturing
can be attributed to several unique advantages which are
generally applicable to the entire range of materials
processing applications, such as high productivity, non-
contact processing, elimination of nishing operations,
adaptability to automation, reduced processing cost,
improved product quality, greater material utilisation,
minimal heat-affected zone (HAZ) and green manufactur-
ing, etc. [1]. Materials processed by laser beam machining,
range from metals and alloys to inorganic as well as
organic non-metals, composites and rocks, etc. [2]. Pulsed
Nd:YAG laser beam can be effectively used for cutting of
silicon nitride ceramics and proper selection and control-
ling of laser beam machining process parameters can
generate good quality cut surface during cutting of
engineering ceramics [3]. Nd:YAG laser machining system
can be continuously operated from a few watts to several
hundred watts, but in most applications pulsed operation is
preferred. Taper formation is the most important char-
acteristics during laser micro-hole percussion drilling
operation due to the inherent focusing characteristics of
the laser machining process [4]. In multiple pulse laser
percussion drilling, entry hole diameter is normally larger
than exit hole diameter and thus the holes drilled are
generally positively tapered [5]. Also, non-uniform melts
ARTICLE IN PRESS
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0890-6955/$ - see front matter r 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2005.10.016

Corresponding author. Tel.:+91 33 483 3353; fax: +91 33 414 6153.

E-mail addresses: arunanshu@rediffmail.com, bdoloionline@rediff-
mail.com, bb13@rediffmail.com (B. Bhattacharyya).
ejection erosion to the hole walls and laser power reduction
as the beam propagated to the hole can be identied as
causes for taper formation [6]. Laser-drilled holes in aero-
engine components must comply with strict quality
standards that determine them suitable for in-service use
[7].
In this paper, experimental investigations into CNC
pulsed Nd:YAG laser micro-drilling of zirconium oxide
(ZrO
2
) have been carried out. Inuence of laser machining
parameters on HAZ thickness and phenomena of tapering
of machined micro-holes has been experimentally investi-
gated. ZrO
2
is very popular engineering ceramic and these
ceramics are extensive used in production of bearings,
thread guide, pressure sensor, infrared radiator, oxygen
sensor, pH meter, and fuel cells, etc. [8] due to their
superior properties such as, low co-efcient of friction,
good wear and corrosion resistance, low thermal con-
ductivity, relatively high thermal expansion co-efcient,
good thermal shock resistance, and high fracture toughness
etc. In order to achieve higher machining rate and accuracy
during laser micro-drilling on hard engineering ceramics
specially ZrO
2
, intensive research is needed to develop
mathematical modeling of Nd:YAG laser performance
criteria correlating various parameters. Attempt has also
been made to carry out optimal parametric analysis on
pulsed Nd:YAG laser micro-machining process, to achieve
better control of machined micro hole quality on ZrO
2
ceramics.
2. Nd:YAG laser system used for micro-drilling operation
For efcient machining operation such as prole cutting,
drilling, marking etc, the CNC Nd:YAG laser machining
system consists of the various subsystems such as; Laser
source and Beam delivery unit, Power supply unit, radio
frequency (RF) Q-switch driver unit, cooling unit and
CNC controller for X,Y and Z axes movement. Laser head
consists of Nd:YAG rod and krypton arc lamp which are
placed in two different focal point of an elliptical cavity.
Lasing medium in Nd:YAG lasers is neodymium atoms
are embedded in yttrium aluminium garnet crystal
host. Pump source is usually a krypton arc lamp. Nd:YAG
crystal is excited by krypton arc lamp. For amplication
of light, optical feedback is provided with 100% reectivity
rear mirror, and a front mirror of reectivity 80%.
The Q-switching is an excellent method to produce
very short pulse width and very high peak power
of laser light from a CW low-power laser. RF Q-switch
driver unit supplies RF signal to Q-switch for its opera-
tion. Using beam delivery system, the laser is focused
on work spot. Main power supply unit controls the
laser output by controlling intensity of light emitted by
krypton arc lamp. Cooling unit cools the system to avoid
thermal damage of laser cavity, lamp, Nd:YAG rod and
Q-switch.
The CNC controller consists of XYZ axes and
controlling unit named Accupos. Stepper motors are
attached to each axis and connected to the Accupos. This
Accupos unit can control the axis through computer unit.
Fig. 1 shows the schematic representation of CNC
Nd:YAG laser machining system. CNC Z-axis controller
unit controls the Z-axis movement of lens. Over the table
to hold work piece, the developed xture is placed. It takes
care of the job posture. CCD camera together with CCTV
monitor is used for viewing the location of work piece and
also for checking the proper focusing condition of surface
of work piece before laser machining for achieving high-
quality laser micro-machining characteristics.
3. Experimental planning based on Response Surface
Methodology
In the present experimental study, laser beam micro-
drilling operation has been performed on zirconia (ZrO
2
)
ceramics of size of 20 20 mm and 1 mm thick. Major
properties of zirconia are listed in Table 1. To determine
the multi-parametric optimal combinations for pulsed
Nd:YAG laser beam micro-drilling process of non-
conducting engineering ceramics, present set of experi-
ments have been carried out according to the central
composite rotatable second-order design based on Re-
sponse Surface Methodology (RSM). Selection of the
range of lamp current, frequency of Q-switch i.e. pulse
frequency, air pressure and pulse width setting has been
made after performing some pilot experiments using xed
focal length.
A well-designed experimental plan can substantially
reduce the total number of experiments. Central composite
designs (CCD) are one of those means. Response surface
modelling has been made to establish the mathematical
relationship between the response, y
u
and the various
machining parameters. General second-order polynomial
response surface mathematical model, which is considered
to analyse the parametric inuences on the various
ARTICLE IN PRESS
Work surface
Motor
Y-Axis

CNC
CONTROLLER
WORK TABLE
Supply of Gas Jet
to the Nozzle
Motor
X-Axis
Motor
Z-Axis
REAR MIRROR, R=100%
Focusing lens
COOLING UNIT

Chiller
Unit
Chilled
Di-Ionised
Water
Tank
Q-SWITCH
Nd:YAG
ROD
KRYPTON
ARC
LAMP
FRONT MIRROR, R=80%
Fig. 1. Schematic representation of CNC Nd:YAG laser machining
system.
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1302
response criteria as follows [9,10]:
y
u
b
0

X
n
i1
b
i
x
iu

X
n
i1
b
ii
x
2
iu

X
ioj
b
ij
x
iu
x
ju
e
u
(1)
here, y
u
, is the corresponding response, e.g. Taper and
HAZ thickness of the laser beam micro-drilling process, x
iu
the coded values of the i
th
machining parameters for u
th
experiment, n the nos. of machining parameters, b
i
, b
ii
, b
ij
the second-order regression coefcients, The residual e
u
is a
measure of experimental error of the u
th
the observations.
Randomised experimental run has been carried out to
minimise the error due to machining set-up. Range of lamp
current, frequency of Q-switch, air pressure and pulse
width setting for the experiments have been selected as
listed in Table 2. Experiments have been carried out
according to the experimental plan based on central
composite rotatable second-order design. Experimental
planning consists of experiment run order, standard order
and coded values have been listed in Table 3.
Thickness of the work samples of zirconia (ZrO
2
)
ceramics has measured by the digital vernier calliper
having least count of 0.001 mm. Work sample has mounted
on machining table of the laser machining system with help
of the developed xture. Diameters of the machined micro-
holes, average thickness of heat affected zone along the
radial direction are measured at 10 magnication with
the help of optical measuring microscope (Olympus
STM6). Microscopic views of machined micro-holes are
also taken for further analysis. HAZ thickness of the
drilled hole has been calculated as follows:
HAZ thickness

HAZ_diameter
Top
hole_diameter
Top

2
. 2
For measuring taper of machined micro-hole, the top
diameter and the bottom diameter of the micro-drilled hole
have been measured with the help of Optical Measuring
Microscope (Olympus STM6) at 10 magnication. After
measuring the difference between top and bottom diameter
and thickness of sample at the drilling spot, considering
formation of straight taper, taper of the machined hole has
been calculated as follows:
Taper

top diameter of hole bottom diameter of hole

2 thickness of workpiece
.
3
The observed data from the set of experiments have been
used as inputs to MINITAB software to establish
mathematical models and analysis of the parametric
optimisation for achieving minimum HAZ and taper
condition during pulsed Nd:YAG laser micro-drilling on
ZrO
2
.
4. Mathematical modelling for the heat affected zone (HAZ)
and taper
Experimental test results of the thickness of heat affected
zone and taper as listed in Table 3 obtained from planned
set of experiments based on central composite rotatable
second-order design have been utilised for the development
of mathematical relationships between two responses with
Nd:YAG laser micro-drilling process parameters. Mathe-
matical model based on RSM for correlating the thickness
of HAZ and taper with various predominant laser
machining process parameters as considered in the experi-
mental design has been established as follows:
y
HAZ
0:3796 0:07888l 0:04120f 0:04301p 0:00570w
0:02146l
2
0:00957f
2
0:00266p
2
0:01234w
2
0:02228l f 0:00679l p 0:03158l w
0:01341f 0:00983f w 0:00497p w, 4
ARTICLE IN PRESS
Table 1
List of properties of zirconia [11,12]
Properties Unit Values
Density gm/cc 5.9
Specic heat J/kg K 500
Thermal conductivity cal/s/cm
2
/1C/cm 0.0047 at 100 1C
0.0055 at 1000 1C
Yield strength GPA 4.0
Modulus of elasticity GPA 200
Flexture strength MPa 634
Hardness GPA 10
Fracture toughness MPa Om 8
Melting temperature 1C 2600
Table 2
List of the actual and corresponding coded values for each parameter
Parameter Unit Symbol Levels
2 1 0 1 2
lamp current amp l 17 19 21 23 25
Pulse frequency i.e. frequency of Q-switch kHz f 1 2 3 4 5
Air pressure kg/cm
2
p 0.6 1 1.4 1.8 2.2
Pulse width % w 2 6 10 14 18
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1303
y
Taper
0:07253 0:00912l 0:00887f0:00606p 0:00449w
0:00153l
2
0:00225f
2
0:00233p
2
0:00399w
2
0:00431l f 0:00646l p 0:00519l w
0:00110f p 0:00023f w 0:07253p w. 5
Response surface regression analysis of HAZ thickness
and taper versus different inuencing parameter has been
made using coded units. From the analysis it can be
concluded that lamp current, pulse frequency, assisted air
pressure, square effect of lamp current interaction between
lamp current and pulse frequency and interaction between
lamp current and pulse width are signicantly inuencing
for controlling HAZ thickness as the p-value of each term
are less than 0.05. Lamp current, pulse frequency, assisted
air pressure and interaction between lamp current and
assisted air pressure are signicantly inuencing for
controlling taper formation as the p-value of each term
are less than 0.05. The other different terms are less
signicant for respective responses. To test the developed
model whether the data is well tted in the model or not,
the calculated S value of the regression analysis for HAZ
thickness and taper are obtained as 0.03956 and 0.01057,
respectively, which are smaller and R
2
value for both the
responses are 92.0% and 80.6%, respectively. The value of
R
2
(adj) for HAZ thickness and taper are 85.0% and
63.6%, respectively. These are moderately high therefore
the model ts the data. Hence, the data for each response
are well tted in the developed models.
Analysis of variance (ANOVA) and subsequently F-ratio
test and p-value test have been carried out to test the
adequacy of the developed mathematical models for
HAZ thickness as well as taper of the micro-hole generated
by pulsed Nd:YAG laser drilling on ZrO
2
. Table 4
shows the results of analysis of variance for HAZ thickness
and taper. P-value of the source of regression model and
linear effects are much lower than 0.05 for both the
responses. Developed second-order regression model for
HAZ is signicant and the linear, square as well as
interaction of parameters on HAZ thickness is signicant.
Also, the second-order regression model for taper is
signicant and the linear effects of process parameters are
signicant. Calculated F-value of the lack-of-t for HAZ
thickness and Taper are 1.93 and 0.66, respectively, which
are much lower than the critical value of the F-distribution
4.06 as found from the standard table at 95% condence
level. Therefore, the developed second-order regression
ARTICLE IN PRESS
Table 3
Experimental plan showing coded values of process parameter setting and observed responses
Run order/expt. no. Std. order Coded values Responses
Lamp current Pulse frequency Air pressure Pulse width HAZ thickness (mm) Taper
1 20 0 0 0 0 0.4217 0.0612
2 5 1 1 1 1 0.2896 0.0583
3 13 1 1 1 1 0.2871 0.0880
4 1 1 1 1 1 0.3132 0.0504
5 14 1 1 1 1 0.4354 0.0611
6 19 0 0 0 0 0.4111 0.0880
7 12 1 1 1 1 0.3783 0.1293
8 7 1 1 1 1 0.2439 0.0732
9 16 1 1 1 1 0.3528 0.0913
10 3 1 1 1 1 0.3139 0.0747
11 11 1 1 1 1 0.3308 0.0824
12 10 1 1 1 1 0.5976 0.0877
13 15 1 1 1 1 0.3004 0.0890
14 2 1 1 1 1 0.6167 0.0881
15 6 1 1 1 1 0.5169 0.0769
16 8 1 1 1 1 0.4125 0.0898
17 9 1 1 1 1 0.4475 0.0891
18 4 1 1 1 1 0.5181 0.1057
19 17 0 0 0 0 0.3858 0.0696
20 18 0 0 0 0 0.3604 0.0651
21 27 0 0 0 2 0.3101 0.0851
22 22 2 0 0 0 0.5826 0.1005
23 25 0 0 2 0 0.4483 0.0966
24 24 0 2 0 0 0.2268 0.0991
25 30 0 0 0 0 0.3333 0.0898
26 28 0 0 0 2 0.2891 0.0885
27 23 0 2 0 0 0.3946 0.0606
28 26 0 0 2 0 0.2709 0.0638
29 21 2 0 0 0 0.2870 0.0534
30 29 0 0 0 0 0.3565 0.0616
31 31 0 0 0 0 0.3886 0.0725
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1304
models for HAZ and taper are adequate at 95% condence
level.
5. Parametric analysis on pulsed Nd:YAG laser machining
characteristics
Inuences of the process parameters such as the lamp
current, frequency of Q-switch or pulse frequency, assisted
air pressure and pulse width on both machining responses
i.e. HAZ thickness and taper during laser micro-drilling on
1 mm thick zircoina have been analysed based on the
developed mathematical model as established through
RSM.
5.1. Analysis of parametric inuences on HAZ thickness
From the RSM-based developed mathematical model,
the combined effects of lamp current and pulse frequency
on HAZ thickness are shown in Fig. 2. Air pressure and
pulse width are taken as constant at 0.6 kg/cm
2
and 2% of
the duty cycle, respectively. It is observed that HAZ
thickness increases with lamp current during micro drilling
operation on zircoina because the energy of laser beam
mainly depends on lamp current. High lamp current
generates high thermal energy, which produces high HAZ
thickness. At low pulse frequency, peak power of the laser
beam is higher. Keeping frequency at low level, the increase
in lamp current resulting in excessive removal of material.
As a result, HAZ thickness increases with lamp current at a
faster rate. But at the higher pulse frequency as peak power
of laser beam is lower, the amount of variation in HAZ
thickness due to increase in lamp current is comparatively
lower. Within the range of pulse frequency (15 kHz),
variation in HAZ thickness is very less at lower range of
lamp current. At higher lamp current, higher value of pulse
frequency causes less heat generation and as a result heat
affected zone is smaller compared to the HAZ condition at
lower value of pulse frequency. The beam energy is much
lower at parameter setting of lower lamp current and
higher pulse frequency, causes low HAZ thickness.
Combined effects of the lamp current and assist air
pressure on HAZ thickness are exhibited in Fig. 3. Pulse
frequency and pulse width are taken as constant value of
2.0 kHz and 2% of the duty cycle, respectively. Surface plot
reects that assisted air pressure has an almost linear
relationship with HAZ thickness at constant lamp current
and HAZ thickness varies non-linearly with lamp current.
Low-assisted air pressure is unable to remove the excess
heat generated at the micro-drilling zone as well as unable
to assist the removal of ejected material. This phenomenon
causes high heat affected zone. However, at higher level of
assist air pressure the amount excess heat has been
removed rapidly and also helps to eject molten material.
As a result low HAZ thickness has been observed.
Variation in HAZ thickness with air pressure at low lamp
current is very low due to low heat generation.
ARTICLE IN PRESS
Table 4
Results of analysis of variance for HAZ thickness and taper
Source HAZ thickness Taper
F-value P-value F-value P-value
Regression 13.12 0.000 4.74 0.002
Linear 37.59 0.000 11.75 0.000
Square 3.63 0.027 1.47 0.258
Interaction 3.14 0.031 2.25 0.092
Lack-of-t 1.93 0.217 0.66 0.730
25
23
21
1
0.1
L
a
m
p

C
u
r
r
e
n
t
,
0.2
0.3
0.4
0.5
2
0.6
0.7
0.8
0.9
19
1.0
3
4
H
A
Z

T
h
i
c
k
n
e
s
s
17
5 Frequency, (kHz)
Pulse Width: 2.0%.
Air Pressure: 0.6 kg/sq.cm;
Hold values:
(
m
m
)
(
a
m
p
)
Fig. 2. Surface plot of HAZ thickness with lamp current and frequency at
air pressure of 0.6 kg/cm
2
.
25
23
21
0.5
0.0
L
a
m
p

C
u
r
r
e
n
t
,
0.1
0.2
0.3
0.4
1.0
0.5
0.6
0.7
0.8
0.9
19
1.5
H
A
Z

T
h
i
c
k
n
e
s
s
,
2.0
17
Air Pressure, (kg/sq.cm)
Pulse Width: 2.0%.
Frequency: 2.0 kHz;
Hold values:
(
m
m
)
(
a
m
p
)
Fig. 3. Response surface plot of HAZ thickness with lamp current and air
pressure.
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1305
Fig. 4 exhibits variation of HAZ thickness with lamp
current and pulse width, while air pressure and pulse
frequency are considered as xed at 2.0 kg/cm
2
and
2.0 kHz, respectively. But at low pulse width, highly
concentrated laser beam causes easy penetration into the
material compared with the high pulse width, as a result
less heat affected zone is generated. In the lower range of
the pulse width, HAZ thickness increases rapidly with lamp
current as higher lamp current produces high energy of
laser beam incident on the material.
Fig. 5 represents optimisation results for the minimum
HAZ thickness based on the developed mathematical
model presented by Eq. (4). In order to minimise the
response i.e. HAZ thickness, equal importance is to be
given on the target and the upper bound of the linear
desirability function. For linear desirability function (d),
the value of weight is considered as 1. Using MINITAB
Software for optimisation laser micro-drilling on zirconia
ceramics, minimum HAZ thickness has been obtained as
0.0675 mm when the lamp current, pulse frequency,
assisted air pressure and pulse width are set at optimal
parametric setting i.e. 17 amp, 2.0 kHz, 2.0 kg/cm
2
and 2%
of the duty cycle, respectively. Fig. 6 shows the Micro-
scopic views of the micro hole drilled with minimum HAZ
thickness.
5.2. Analysis of parametric inuences on taper
During pulsed Nd:YAG laser micro-hole drilling opera-
tion, minimisation of taper of micro hole is highly needed
for maintaining quality and accuracy of the hole. There-
fore, inuences of the laser machining parameters such as
lamp current, frequency of Q-switch or pulse frequency,
assisted air pressure and pulse width on taper phenomena
during laser micro-drilling on 1 mm thick zircoina, has
been analysed based on the developed mathematical model
as obtained through RSM.
Fig. 7 shows effect of lamp current and pulse frequency
on taper keeping air pressure and pulse width constant at
0.6 kg/cm
2
and 2% of the duty cycle, respectively. It is
observed that taper increases with the lamp current
signicantly irrespective of pulse frequency. The nature of
variation of the taper with applied lamp current is almost
similar for the different pulse frequency and the nature of
variation is almost linear. It is due to the fact that energy of
laser beam mainly depends on lamp current. High lamp
current generates high thermal energy, as a result top
surface of work sample where the laser beam is focused, get
melted and vapourised instantly and large volume of
material is removed from the top surface during penetra-
tion into the remaining thickness, which produces large
taper. The low energy of laser beam generates small taper.
From the response plot it has been observed that the taper
ARTICLE IN PRESS
25
23
21
19
17
Pulse Width, (%)
Frequency: 2.0 kHz;
Hold values:
H
A
Z

T
h
i
c
k
n
e
s
s
,
(
m
m
)
0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
10
20
Air Pressure: 2.0 kg/sq.cm.
L
a
m
p

C
u
r
r
e
n
t
,
(
a
m
p
)
Fig. 4. Plot of variation of HAZ thickness with lamp current and pulse
width.
Fig. 5. Optimisation results for minimum HAZ thickness.
HAZ Thickness
(a) (b)
Fig. 6. Microscopic views of the micro hole drilled with minimum HAZ thickness: (a) top surface, (b) bottom surface.
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1306
almost linearly varies with pulse frequency. At very high
pulse frequency, relatively large taper is observed but at
low pulse frequency, low taper is generated. At very low
pulse frequency, the beam energy is slightly high but time
between two successive incident beams is more, therefore,
material has been removed only from the narrow focusing
spot on the top surface of work sample. The assisted air
pressure is also low therefore very narrow localised heating
has been occurred as a result low tapered hole is generated.
Again at high pulse frequency, beam energy is less but the
time between two successive incident beam is very small,
therefore the top surface gets heated rapidly and generates
large taper of micro-hole.
The effects of lamp current and assist air pressure on
taper have been shown in Fig. 8. Pulse frequency and pulse
width are taken as 2.0 kHz and 2% of the duty cycle,
respectively. The surface plot reects that assisted air
pressure has non-linear effect on taper at different lamp
current. At lower level of assisted air pressure, the variation
in taper with lamp current is much more, but at the higher
level of assisted air pressure, variation in taper is
comparatively less with respect to lamp current. At lower
level of lamp current, taper is signicantly increasing with
the increase in assisted air pressure. At low lamp current
the amount of heat generation is much lower causing slow
rate of material removal. Zirconia has a very low thermal
conductivity and the higher assisted air pressure cools
localised heating zone causing slower rate of material
removal to penetrate up to the whole thickness of the work
sample. For drilling the whole depth of workpiece at higher
pressure of assist air, but at lower lamp current, the
required drilling time becomes more. As a result laser beam
energy for longer period causing large area material
removal from the top surface of the drilled hole, resulting
an increase in taper with the increase in assisted air
pressure. But at the higher level of lamp current, high-
energy laser beam removes greater amount of material and
as a result, a large diameter of the top surface is obtained
with low air pressure and required drilling time is also very
less. In higher level of lamp current, increase in assisted air
pressure helps to remove the extra heat, which causes less
material removal from the top surface, as a result taper is
decreasing with the increasing in assisted air pressure at
higher level of lamp current.
Fig. 9 exhibits effect of lamp current and pulse width on
taper keeping air pressure and pulse frequency constant at
0.6 kg/cm
2
and 2.0 kHz, respectively. At the lower pulse
width, variation in taper formation is very large with the
increase in lamp current, but at the higher pulse width,
increases in lamp current results very little variation of
taper. Because at low pulse width high concentrated laser
beam energy causes faster rate of penetration compared to
high pulse width, as a result less taper is formed.
Fig. 10 shows optimisation results for the minimum
taper based on the developed mathematical model i.e.
Eq. (5). In order to minimise the response i.e. taper, equal
importance is to be given on the target and the upper
bound of linear desirability function. For linear desirability
function (d), the value of the weight is considered as 1.
Using MINITAB Software for optimisation the laser
micro-drilling on zirconia ceramics, minimum of taper of
micro-hole has been obtained as 0.0319 when the lamp
current, pulse frequency, assisted air pressure and pulse
width are set at optimal parametric setting i.e. 17 amp,
2.0 kHz, 0.6 kg/cm
2
and 2% of the duty cycle, respectively.
Fig. 11 shows the Microscopic views of micro-hole drilled
with minimum taper.
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23
21
1
0.02
L
a
m
p

C
u
r
r
e
n
t
,
2
0.12
19
0.22
3
4
T
a
p
e
r
17
5 Frequency, (kHz)
Pulse Width: 2.0 %.
Air Pressure: 0.6 kg/sq.cm;
Hold values:
(
a
m
p
)
Fig. 7. Response surface plot of taper with lamp current and pulse
frequency.
T
a
p
e
r
Hold values:
0.5
0.05
0.10
1.0
0.15
0.20
1.5
2.0
Air Pressure, (kg/sq.cm)
Pulse Width: 2.0 %.
Frequency: 5.0 kHz;
25
23
21
L
a
m
p

C
u
r
r
e
n
t
,
19
17
(
a
m
p
)
Fig. 8. Response surface plot of taper with lamp current and air pressure
at high pulse frequency of 5.0 kHz.
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1307
5.3. Multi objective optimisation analysis during micro-
drilling of ZrO
2
Multi response optimisation analysis for micro-drilling
operation on zirconia has been carried utilising MINITAB
software and optimisation results for HAZ and taper are
shown in Figs. 12 and 13. HAZ thickness and taper have
been optimised together in one setting and represented in
Fig. 12. Each column of the graph corresponds to a factor.
Each row of the graph corresponds to a response variable.
Each cell of the graph shows how one of the response
variables changes as a function of one of the factors, while
all other factors remain xed. The numbers displayed at the
top of a column show the current factor level settings and
the high and low factor settings in the experimental design.
At the left of each row, goal for the response (minimum),
predicted response, y, at current factor settings, and
individual desirability score are given. The current para-
meter settings are lamp current of 17 amp; pulse frequency
of 1.6245 kHz; assisted air pressure of 1.0437 kg/cm
2
and
pulse width of 2% of duty cycle for achieving the predicted
minimum value of HAZ thickness (y
HAZ
) of 0.1296 mm
and minimum taper (y
taper
) of 0.040. The composite
desirability, D is displayed in the upper left corner of the
graph and the value of composite desirability is 1. The label
above composite desirability refers to the current setting
and changes for moving the factor settings interactively.
When the optimisation plot is created, the label is optimal.
The vertical lines inside the graph represent current factor
settings. Horizontal dotted lines represent the current
response values.
Fig. 13 shows overlaid contour plot and white area,
which reects the feasible region. The feasible region is the
area formed by the two signicant process parameter i.e.,
lamp current and pulse frequency, keeping other design
variables constant, such that the acceptable values for each
response are lays between their respective contours. The
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21
0
L
a
m
p

C
u
r
r
e
n
t
,
0.05
0.10
19
0.15
10
T
a
p
e
r
17
20
Pulse W
idth, (%
)
Air Pressure: 0.6 kg/sq.cm.
Frequency: 2.0 kHz;
Hold values:
(
a
m
p
)
Fig. 9. Response surface plot of taper with lamp current and pulse width.
Fig. 10. Optimisation results of taper.
(a) (b)
Fig. 11. Microscopic views of the micro hole drilled with minimum taper: (a) top surface, (b) bottom surface.
Fig. 12. Optimisation results for minimum HAZ thickness and taper.
A.S. Kuar et al. / International Journal of Machine Tools & Manufacture 46 (2006) 13011310 1308
feasible region selected for HAZ thickness is 0.16 mm for
upper value and 0.12 mm for lower value respectively. For
taper the upper and lower values are selected as 0.038 and
0.042, respectively and the overlaid feasible region is
displayed as white region in the gure. The other two
parameters, assisted air pressure and pulse width value are
set at constant i.e. 1.0 kg/cm
2
and 2% of duty cycle,
respectively.
6. Conclusions
The Nd:YAG laser machining system has capability to
perform successful micro-drilling operation on zirconium
oxide and the process parameters can be optimally
controlled for achieving minimum HAZ thickness and
taper formation. During micro-drilling operation on
Zirconia by Pulsed Nd:YAG laser, lamp current has very
signicant effect on both the responses, i.e., HAZ and taper
compare to other three controlling parameter. HAZ
thickness and taper both are increased with the increase
in lamp current almost linearly. The optimum values of
these two responses have been found at the low value of
lamp current. Pulse frequency of the Nd:YAG laser beam
machining system, has square effect on both the responses
during micro-drilling operation on zirconia. Although
HAZ thickness shows an increasing tendency with the
increasing pulse frequency value, taper shows a little
variation with the pulse frequency. The taper initially
decreases with pulse frequency, but increases gradually
with pulse frequency after reaching the minimum value of
taper. The increase in assisted air pressure has almost linear
decreasing effect on HAZ thickness. But due to the lower
thermal conductivity of zirconia, taper is increased with the
increase in assisted air pressure for zirconia at lower lamp
current but it decreases with the increase of assisted air
pressure at higher range of lamp current. HAZ thickness
has an increasing slight curvilinear nature with the increase
in pulse width. The optimum value of HAZ thickness has
been found from the developed mathematical model at the
lower range of pulse width like other response taper. Taper
formation is also increasing with the increase in pulse width
at lower range of lamp current i.e. at lower energy level but
it becomes insignicant on higher-energy level of laser
beam i.e. at higher range of lamp current setting. There are
further scope of research works to nd out the optimal
laser parameters setting for other important machining
criteria such as shape geometry of the hole, recast layer
formation, micro-crack and surface texture etc. on the
micro drilled hole. The present set developed mathematical
models and optimal analysis will be very much effective
and useful for achieving high quality precision micro-
machining operation on engineering ceramics by CNC
pulsed Nd:YAG laser.
Acknowledgements
The authors acknowledge the nancial support
from DST, New Delhi under the scheme of DST SERC
Fast Track Project and UGC under the CAS Ph-III
program.
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