i2m2 colloquium – 16 December 2022

Presenter: Kerim YILDIRIM, Department of Mechanical Engineering, KU

Leuven, Belgium

Title: Real-time monitoring of surface texturing in femtosecond laser

micromanufacturing by using structure-borne acoustic emission sensors

Abstract: There is a market trend to smaller and more accurate micro structures, which demands a
higher level of precision and efficiency in laser surface structuring process. Femtosecond laser (FSL)
texturing is an effective method to manufacture microfeature of excellent surface quality and
accuracy and to enhance the functionalization of medical devices, micromechanical components, and
moulds. However, FSL texturing remains challenging work and leads to imperfect removal states due
to a large number of process variables and chaotic ablation dynamics. In this context, an in-situ
inspection is necessary, in order to improve the process reproducibility and quality through a closed-
loop control and early dimension detection of texture. Acoustic emission (AE) is one of the common
non-destructive real-time detection techniques for capturing local changes in materials, which can be
used for monitoring the fs laser-induced ablation. Laser-induced shock waves are measured for the
changes in laser parameters such as laser fluence throughout the processing period. Altered process
parameters are attributed to the changes in the textured surface geometry. This research illustrates
how structure-borne AE monitoring can be expanded to fs laser micromachining by correlating AE
signals to the profile of the texture geometry.

Biography: Kerim Yildirim obtained his Master’s degree in Materials Engineering with a specialization
in Materials Science of Metals from RWTH Aachen University in 2020. He is currently a PhD researcher
in the department of Mechanical Engineering at KU Leuven, Belgium. His main research interest
centres on real-time monitoring of femtosecond laser micromachining process. He is also concerned
about ultra-high precision laser-based manufacturing for various industries such as aerospace and
electronics industries. Currently, he is focusing on the relation between the acoustic emission signals
and ultra-short pulse laser micromachining of metals to improve process quality and precision by
implementing novel in-situ process monitoring approaches.
I2M2 COLLOQUIUM – 16 DECEMBER 2022

Presenter: Shayan Bayki, Department of Mechanical Engineering,

Indian Institute of Technology Bombay, India

Title: Modeling of Electrical Discharge Machining Plasma

Abstract: In electrical discharge machining (EDM), the plasma formed

in the dielectric-filled inter-electrode gap drives the material removal
process via melting and vaporization. While several studies have
obtained a description of EDM plasma experimentally or via empirical
models, there is a limited understanding of the complex physical
phenomena like the distribution of temperature, electron density,
and the electric field between electrodes. This research presents a one-dimensional physics-based
model of electrical discharge machining plasma with air as the dielectric medium (dry-EDM).
Governing equations of particle balance (drift-diffusion) and energy balance are solved together to
predict plasma properties such as electron and chemical species density, plasma temperature, plasma
potential and current, and heat flux to the electrodes as a function of axial distance along the inter-
electrode gap and time. The model offers key insights into the effect of EDM process parameters on
the above-mentioned plasma properties paving pathways for process improvements.

Biography: Shayan Bayki is a Ph.D. student at the High Performance and Sustainable Manufacturing
Laboratory in the Department of Mechanical Engineering, IIT Bombay, India. Before joining IIT
Bombay, Shayan worked as a production manager at Fartak Co. in Iran for about two years, where he
was responsible for making plasma-based purification devices. Shayan has a B.Sc. degree from Guilan
University, Iran, in Solid-state Physics and an M.Sc degree from Amirkabir University of Technology,
Iran. Shayan was awarded a gold medal for his excellent academic achievements during his B.Sc. in
2012 and received a scholarship to pursue his M.Sc. degree. His M.Sc. thesis focused on the
development of a DC plasma sputtering-based deposition of metallic (Al and Cu) targets. At IIT
Bombay, Shayan's research interests lie in the plasma processing of materials for surface treatment,
disinfection, or for material removal, such as in electrical discharge machining.