EXPERIMENTAL STUDY ON SHRINKAGE OF NARROW

PARTS PRODUCED BY LASER CUTTING

Adnan Mustafić, University of Tuzla, B&H,

Elvedin Trakić, University of Tuzla, B&H,
Almir Osmanović, University of Tuzla, B&H,
Joško Valentinčić, University of Ljubljana, Slovenia

ABSTRACT:
In the present study, the effects of dimensional parameters of narrow parts on dimensional deviations were
investigated in order to determine the ideal cutting conditions for stainless steel sheets. For this purpose, the
laser cutting tests were conducted on a X5CrNi18-10 steel using a N2 laser. The experimental design was
performed according to Taguchi’s L16 orthogonal array with a mixed level design for sheet thickness, sample
length and sample width. According to the experimental results, which were determined through variance of
analysis (ANOVA), it was determined that the most effective dimensional parameter for minimum shrinkage is
the sample width with a percent contribution of 40,34%.

KEY WORDS: Shrinkage, dimensional deviation, Taguchi technique, laser cutting process, ANOVA

INTRODUCTION

(To be extended)

The nature of the laser cutting process is multifactorial, very complex and
insufficiently known taking into account correlations and interactions between factors.
For the realization of the laser cutting process, knowledge of influencing factors is
needed. By knowing the essence of the process and its dependence on process factors, it
is possible to improve the quality of processing and efficiency, but also to lower the
processing costs [1,2].
A large number of recent scientific studies dealing with the problem of the laser
cutting process mainly describe the variation of the process parameters for different types
of materials and their impact on the quantities from the set of outputs. However, there are
almost no studies indicating to the influence of geometric features and dimensions on
processing errors and the deviation of finished products from the required value. In that
regard, the influence of the dimensions (thickness, width and length) of the machined
sheets of high alloyed steel X5CrNi18-10 on the dimensional deviation (length
deviations) was analyzed within the research.
 EXPERIMENTAL SETUP AND PROCEDURE
The experimental studies were performed by using a 5kW continuous wave mode N2
Prima Power Laser as shown in Figure 1. This laser meets all necessary requirements for the
research objectives and precision of the cut parts.

Prima Power Laser Transparent shielding glass

Moveable bed

Stainless steel sheet Noozle Control board

Figure 1. Experimental setup

In the present study, the laser cutting strips of X5CrNi18-10 steel were carried out with
different sets of workpiece dimensions and fixed laser parameters. Three process parameters
were selected and their effect on the output variable (dimensional deviation) was studied for
the laser cutting process. The chosen input parameters for the experimental study were sheet
thickness, sample length and width. In order to eliminate the influence of the laser cutting
parameters (cutting speed, gas pressure, laser power, focal point position, etc.), in the
research phase were considered constant. The fixed values are listed in Table 1.
Measurements of dimensional deviations (length deviations) were performed on a classic and
robust measuring table using a large multi-gauge.
The laser cutting experiment in this phase of research was planned and realized using
the theory of the planned experiment. In order to minimize the number of experimental tests
required, with the quality of data remaining satisfactory, Taguchi method was applied. The
Taguchi method, based on the application of Taguchi’s orthogonal arrays, is a well-known,
unique and strong technique for improving the quality of products and processes. It represents
a simple and efficient method of planning the experiment, and is not limited to specific
problems, and is most often used for experimental analysis and optimization of products and
processes [2].

Table 1. Laser process parameters

Process parameter Symbol Unit Value
Cutting speed v mm/min 1900
Gas pressure p bar 12,8
Focus f mm -4,5
Used gas - - N2

Assuming that the mutual relations of the selected sizes and experimentally measured
sizes are complex and nonlinear, four levels of thickness and length variation for each
parameter were selected, and two variation levels for the sample width. In that regard, the
most appropriate experimental plan matrix was formed in accordance with the Taguchi
orthogonal array L16 (42 × 21). Three replicates were carried out at each condition with a total
number of 48 experiments. The summary of experimental conditions are listed in Table 2.

Table 2. Control parameters and their levels

Level values
Symbol Parameter Notation Unit
1 2 3 4
A Sheet thickness t mm 2 3 4 5
B Sample length l mm 150 250 350 450
C Sample width w mm 10 20 - -

RESULTS AND DISCUSSIONS

The measured results of dimensional deviations, as well as the transformation of
deviations into S/N ratios are given in Table 3 and Table 4.

Table 3. Taguchi orthogonal array L16 (42 ×21) with experimental results
Levels of
Experimental results
No control factors
Measurement Measurement Measurement Deviation Deviation Deviation
A B C I II III I II III
1 1 1 1 149,875 149,810 149,810 0,125 0,190 0,190
2 1 2 1 249,660 249,700 249,710 0,340 0,300 0,290
3 1 3 2 349,800 349,740 349,780 0,200 0,260 0,220
4 1 4 2 449,610 449,760 449,740 0,390 0,240 0,260
5 2 1 1 149,830 149,875 149,685 0,170 0,125 0,315
6 2 2 1 249,820 249,160 249,590 0,180 0,840 0,410
7 2 3 2 349,705 349,705 349,860 0,295 0,295 0,140
8 2 4 2 449,900 449,790 449,660 0,100 0,210 0,340
9 3 1 2 149,815 149,780 149,795 0,185 0,220 0,205
10 3 2 2 249,820 249,750 249,860 0,180 0,250 0,140
11 3 3 1 349,610 349,670 349,520 0,390 0,330 0,480
12 3 4 1 449,370 449,460 449,430 0,630 0,540 0,570
13 4 1 2 149,770 149,750 150,000 0,230 0,250 0,000
14 4 2 2 250,000 249,810 250,000 0,000 0,190 0,000
15 4 3 1 349,530 349,560 - 0,470 0,440 -
16 4 4 1 449,280 449,150 449,450 0,720 0,850 0,550
Since the aim of this study was to reduce the dimensional deviation, the “smaller-is-better”
characteristics were selected and calculated as follows [3]:
1 n 
S / N  10  log   Yi 2  (1)
 n i 1 

Table 4. Taguchi orthogonal array L16 (42 ×21) with experimental results and calculated S/N ratios
Levels of
Experimental results Calculated S/N ratios
No control factors
(Smaller-is-better)
A B C Deviation I Deviation II Deviation III
1 1 1 1 0,125 0,190 0,190 15,3350
2 1 2 1 0,340 0,300 0,290 10,1517
3 1 3 2 0,200 0,260 0,220 12,8400
4 1 4 2 0,390 0,240 0,260 10,3417
5 2 1 1 0,170 0,125 0,315 13,1951
6 2 2 1 0,180 0,840 0,410 5,1995
7 2 3 2 0,295 0,295 0,140 11,9010
8 2 4 2 0,100 0,210 0,340 12,4744
9 3 1 2 0,185 0,220 0,205 13,8143
10 3 2 2 0,180 0,250 0,140 14,1832
11 3 3 1 0,390 0,330 0,480 7,8569
12 3 4 1 0,630 0,540 0,570 4,7134
13 4 1 2 0,230 0,250 0,000 14,1492
14 4 2 2 0,000 0,190 0,000 19,1961
15 4 3 1 0,470 0,440 - 6,8351
16 4 4 1 0,720 0,850 0,550 2,8864

According to the Taguchi methodology, the response table for S/N ratios and data means
were used for the effect analysis of the control factors on the dimensional deviation. The S/N
response table, as well as the response table of means are given in Table 5.

Table 5. Response table for S/N ratios and means

Response Table for S/N Ratios
Response Table for Means
(Smaller is better)
Level A B C Level A B C
1 12,167 14,123 8,272 1 0,2504 0,1837 0,4125
2 10,693 12,183 13,612 2 0,2850 0,2600 0,2000
3 10,142 9,858 - 3 0,3433 0,3313 -
4 10,767 7,604 - 4 0,3463 0,4500 -
Delta 2,025 6,519 5,341 Delta 0,0958 0,2663 0,2125
Rank 3 1 2 Rank 3 1 2

As shown in Table 5., the effects of investigated parameters are estimated based on the
average S/N ratios and means for the dimensional deviation. The data values are calculated as
the difference between maximum and minimum mean values, indicating that the sample
length has the most dominant influence on the dimensional deviation followed by the width
and sheet thickness. According to the delta values, the ranking of the investigated
dimensional parameters and the degree of influence on the measured values of dimensional
deviations can be written as: sample length, sample width and sheet thickness.
Graphical interpretation of the measured results on the dimensional deviations given in Table
1. and Table 2., can be presented in means of main effects plot for all investigated parameters
according to Figure 2. This plots are very helpful in visualizing the magnitudes of the
investigated parameters on the response variable. Since the highest S/N ratio gives the best
results (Figure 2) or the minimum dimensional deviation, the ideal sample dimensions are
sheet thickness of 2(mm), sample length of 150(mm) and the sample width of 20(mm). The
optimum factor levels can be shortly given as A1-B1-C2. This illustrates that the dimensional
deviation in the laser cutting process was strongly influenced by the sample length and the
sample width.
Mean of SN ratios for dimensional deviation, (dB)

Thickness (mm) Length (mm) Width (mm)

15

14

13

12

11

10

7
2 3 4 5 150 250 350 450 10 20
Signal-to-noise: Smaller is better

Figure 2. Main effects plot of S/N ratios for dimensional deviation

Thickness (mm) Length (mm) Width (mm)

0,45
Mean of dimensional deviation,(mm)

0,40

0,35

0,30

0,25

0,20

2 3 4 5 150 250 350 450 10 20

Figure 3. Main effects plot for dimensional deviation

In order to study the statistical significance of the investigated parameters the analysis of
variance (ANOVA) was used. The results of ANOVA given in Table 6., for the confidence
level of 95% indicate that sheet thickness, sample length and width influence the dimensional
deviation by 5,85%, 34,33% and 40,34%, respectively. Unlike the response table for data
means and S/N ratios (Table 5.), the ANOVA analysis showed that the sample width had the
most percentile contribution on the dimensional deviation in the laser cutting process.
Another interesting finding from the ANOVA analysis is that the sheet thickness had no
statistical significance on the dimensional deviation since the p-value exceeds the
significance level of 5% (p>0,05). The percentage contribution of 19,48% of the error term
can be attributed to the laser process parameters which in this case were kept constant.

Table 6. Results of ANOVA for dimensional deviation

Degrees of Sum of Mean
F-test p-value Contribution
Source freedom Squares Square
(DF) SS) (MS) F p PC (%)
Thickness (mm) 3 0,02618 0,008725 0,80 0,528 5,85
Length (mm) 3 0,15374 0,051246 4,7 0,036 34,33
Width (mm) 3 0,18063 0,180625 16,57 0,004 40,34
Error 8 0,08723 0,010904 19,48
Total 15 0,44777 100

CONCLUSION
In this study, the Taguchi technique was used in order to determine the effect of the
dimensional parameters of narrow parts in the laser cutting process of X5CrNi18-10 stainless
steel on the dimensional deviation. All experimental results were evaluated using the S/N
quality characteristic and ANOVA
The following conclusions can be extracted from the statistical results:

(1) Based on the results, which were obtained for the smaller-is-better quality
characteristic, it was demonstrated that the optimum dimensional parameter for
minimum dimensional deviations were sheet thickness of 2 (mm), sample length of
150 (mm) and sample width of 20 (mm). The ideal dimensional parameter levels can
be shortly given as A1-B1-C2.
(2) According to the response table for S/N ratios and data means it was found that the
sample length has the strongest effect on the dimensional deviation.
(3) The order of importance of the controllable parameters to the measured output
variable is: sample length, sample width and sheet thickness.
(4) Based on the results of ANOVA, the main parameter affecting the dimensional
deviation was the sample width of 40,34%. The contribution of sample length and
sheet thickness were 34,33% and 5,85%, respectively.
(5) Through the variation of the dimensional parameters in the laser cutting process
despite the constant laser cutting process parameters the heat input into the material
changes the values of dimensional deviations. By increasing the sheet thickness and
sample length and lower sample width results in greater residual stresses and
consequently larger shrinkage. However, in order to determine the accuracy of the
results in such a process, further measurements should be made which could confirm
or reject such an approach to solving industrial problems.
(6) Additional research in the laser cutting process should include the variation of laser
cutting process parameters in order to obtain adequate indicators of dimensional and
geometrical deviations in the treated parts through a systematic approach.

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