Australian Journal of Mechanical Engineering

ISSN: (Print) (Online) Journal homepage: https://www.tandfonline.com/loi/tmec20

Experimental investigation and parametric

optimisation of the hole-circularity and recast
layer during the laser trepan drilling

Kedari Lal Dhaker , Bhagat Singh & Yogesh Shrivastava

To cite this article: Kedari Lal Dhaker , Bhagat Singh & Yogesh Shrivastava (2020):
Experimental investigation and parametric optimisation of the hole-circularity and recast
layer during the laser trepan drilling, Australian Journal of Mechanical Engineering, DOI:
10.1080/14484846.2020.1794522

To link to this article: https://doi.org/10.1080/14484846.2020.1794522

Published online: 22 Jul 2020.

Submit your article to this journal

Article views: 9

View related articles

View Crossmark data

Full Terms & Conditions of access and use can be found at

https://www.tandfonline.com/action/journalInformation?journalCode=tmec20
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING
https://doi.org/10.1080/14484846.2020.1794522

ARTICLE

Experimental investigation and parametric optimisation of the hole-circularity

and recast layer during the laser trepan drilling
Kedari Lal Dhakera, Bhagat Singha and Yogesh Shrivastavab
a
Department of Mechanical Engineering Department, Jaypee University of Engineering and Technology, Guna, M.P., India; bDepartment of
Mechanical Engineering, Jaypee University of Engineering Technology, Guna, India; cDepartment of Mechanical Engineering, Galgotias
College of Engineering and Technology, Greater Noida, India

ABSTRACT ARTICLE HISTORY

Re-solidified layer of molten metal during laser trepan drilling of Inconel-718 is a serious Received 27 April 2020
concern. Re-solidification affects the dimensional stability and geometrical features. Many Accepted 2 July 2020
scientific efforts have been reported for understanding and minimising the re-solidifica­ KEYWORDS
tion layer (recast layer) thickness in laser cutting and percussion drilling operations. However Hole-circularity; recast layer;
till date, limited scientific work has been reported concerning recast layer formation during the re-solidification; laser
laser trepanning of Inconel-718. In the present work, a methodology has been proposed for trepanning; difficult to
reducing the recast layer formation during the laser trepanning of Inconel-718. For under­ machine material
standing and achieving minimum recast layer thickness with better circularity, series of laser
trepanning experiments have been performed on a thin sheet of Inconel-718. Recast layer
thickness and hole- circularity are measured for each laser trepan drilled hole followed by the
development of mathematical models using response surface methodology. The developed
mathematical models are optimised with the help of multi-objective genetic algorithm to
ascertain the optimum trepan drilling parameters. The obtained values of optimum parameters
are validated by conducting more experiments. From validation experiments, it has been found
that the obtained range of input parameters is significant, and the heat affected zone can be
controlled using the proposed methodology.

1. Introduction also studied the laser cutting of titanium alloy sheets

Conventional material removal processes like drilling,
milling, turning, etc. face difficulty in machining the
superalloys with high accuracy and precision. The
rapid industrialisation and need for hard materials in
modern industries have raised the need for accurate
and precise machining of hard and difficult to cut
materials. With the evolution of advanced machining
processes, machining of such hard materials has
become easier. However, accuracy and precision are
still the factors that need to be looked upon. Several
researchers have suggested that the quality of machin­
ing, accuracy, and precision depends on the selection of
input parameters and machining conditions during
trepan drilling (Biscaia, Ribas, and Júnior 2020; Duan
et al. 2020; Saini and Dubey 2019; Dhaker and Pandey
2018; Dhaker, Pandey, and Upadhayay 2017). Research
works have been reported by different researchers con­
cerning the selection of process parameters that may
improve the quality characteristics during machining.
Pandey and Dubey (Pandey and Dubey 2012) have
studied the laser cutting process for the Duralumin
sheet intending to improve the cutting geometry. For
which a robust parameter design methodology for
reducing the kerf width and kerf deviations has been
applied. Pandey and Dubey (Pandey and Dubey 2013)
and created a fuzzy logic-based expert system for qual­
ity characteristics and parameter prediction. Chien and
Huo (Chien and Hou 2007) have studied the behaviour
of the recast layer in laser trepanning drilling of
Inconel-718. Experiments have been performed using
Taguchi based analytical approach for getting reduced
recast layer thickness to 0.038 mm. Goyal and Dubey
(Goyal and Dubey 2016) have studied the laser trepan­
ning drilling for getting better geometrical features in
titanium alloy sheet. For which regression models have
been developed and Genetic algorithm has been imple­
mented. The result shows an improvement in the hole
circularity by 8% and hole taper by 49%. Similarly,
Marimuthu et al. (Marimuthu et al. 2017) have con­
ducted experiments on Quasi-CW-fibre laser for study­
ing the hole quality characteristics of nickel-based
super-alloy during Trepanning Drilling. From the
results, it has been observed that the hole quality char­
acteristics have been improved by controlling the hole
surface roughness, recast layer, oxide layer.
Tamrin et al. (Tamrin et al. 2015) have reduced the
HAZ in laser percussion drilling with the help of grey
relational analysis. Experiments have been performed
on three different thermoplastics at high cutting speed
(0.4 m/min), low laser power (200 W), and low

CONTACT Yogesh Shrivastava yogeshshrivastava90@gmail.com

© 2020 Engineers Australia
2 K. L. DHAKER ET AL.

compressed air pressure (2.5 bar). Dhaker et al. input parameters, and responses has been prepared. In
(Dhaker, Pandey, and Upadhayay 2017) have studied the second stage, experiments have been performed and
the hole size (hole diameter) in laser trepan drilling on responses have been measured. The next stage is dedi­
the Inconel-718 sheet. An improvement in hole dimen­ cated to the mathematical modelling and optimisation of
sions has been obtained with the help of regression the developed models using response surface methodol­
analyses. Hajdarevic and Bijelonja (Begic-Hajdarevic ogy (RSM) and Genetic algorithm (GA). In the final stage
and Bijelonja 2015) have investigated the distribution of the methodology adopted, results are validated by
of temperature by the Finite Element Method (FEM) performing more experiments. The proposed methodol­
and found 13% deviation in hole-diameter during the ogy has been presented in Figure 1.
laser drilling of tungsten alloy. P. Rajesh et al. (Rajesh Trepanning experiments are carried out on a 1.4 mm
et al. 2017) developed response surface method based thick sheet of material Inconel-718 using solid-state
mathematical model for hole geometrical characteris­ 250 W, pulsed Nd: YAG laser machining system. In
tics (taper, circularity at entry/exit,) of laser drilling in this system, the beam of laser light is delivered at work
material austenitic stainless steel and have explored the material sheet in normal to surface direction with the
effect of various input parameters on hole-quality char­ help of CNC controlled motion of delivery nozzle. The
acteristics. From the literature survey, it has been found specification of the drilling system has been shown in
that limited scientific effort has been made in the Table 1. The schematic diagram of the laser trepan
direction of laser trepan drilling operations. Laser tre­ drilling system has been shown in Figure 2.
pan drilling is usually exhibited several geometrical and
metallurgical imperfection such as tapered-hole, poor
circular hole (poor circularity), barrelling, recast layer, 2.1. Material and methods
etc. (Choudhury, Chong, and Vahid 2012). Therefore
Wide engineering applications of nickel-based super­
improving the drilled hole by minimising associated
alloy Inconel-718 have been reported in the advanced
defects that occurred during the laser trepanning dril­
technological fields like gas turbine components, mar­
ling is the major challenge for the manufacturers.
ine equipment, medical equipment, and similar criti­
However, hole features can be improved if the laser
cal application. Compositions of Inconel-718 has been
drilling system is being operated at an optimum level of
mentioned in Table 2. Moreover, the selected input
laser parameters. Hole-circularity and recast layer are
parameters have been done based on past work done
severe defects that deteriorate the precision of the hole
by various researchers. Several factors have confined
and the thermal characteristics of the work material.
the selection of input parameters like; specification of
Furthermore, many researchers have reported that dif­
machine, the feasibility of variation in input para­
ficult to conventionally cut materials can efficiently be
meter, and availability of resources. For the selection
machined using Nd: YAG laser (Ahn, Byun, and Kang
of levels of input parameters pilot experiments have
2010; Almeida et al., 2006; Dubey and Yadava 2008;
Nyon et al. 2012; Sharma and Yadava 2011;
Venkatesan, Ramanujam, and Kuppan 2016),
In the present work, laser trepanning experiments
have been performed on a 1.4 mm thick sheet of mate­
rial Inconel-718. Laser input parameters taken for stu­
dies are; assist gas pressure, laser current, standoff
distance, and trepanning speed. The responses calcu­
lated from the experiments are hole-circularity and
recast layer thickness (µm). Response surface methodol­
ogy (RSM) based mathematical models are developed
for hole circularity and recast layer thickness using
MINITAB17 software. Obtained RSM based models
are further used for finding the optimal range of process
parameters and the same have been evaluated experi­ Figure 1. Flowchart of the proposed methodology.
mentally. From the findings of validation experiments, MOGA = Multi Objective Genetic Algorithm
it is concluded that the obtained range is significant and
suitable for getting reduced recast layer formation with
Table 1. Specification of the drilling system.
acceptable hole-circularity in laser trepan drilled hole. Characteristics Unit Value
Average power W 250
Laser wavelength nm 1064
2. Experimentation Operation mode - Pulsed mode
Pulse width ms 10
The proposed methodology has been divided into four Transmission efficiency % 90
stages; in the first stage, the selection of machine, material, Focused spot diameter µm 400
 AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 3

Table 4. Design of experiments developed using BBD.

Assist Gas Laser Standoff
Exp. Pressure Current Distance Trepanning Hole Recast Layer
No. (X1) (X2) (X3) Speed (X4) Circularity (micrometre)
1 6 200 1.0 30 0.965 211.60
2 10 200 1.0 30 0.922 208.10
3 6 280 1.0 30 0.826 247.10
4 10 280 1.0 30 0.959 189.10
5 8 240 0.8 10 0.841 115.17
6 8 240 1.2 10 0.887 195.91
7 8 240 0.8 50 0.883 201.40
8 8 240 1.2 50 0.842 156.76
9 6 240 1.0 10 0.877 182.20
10 10 240 1.0 10 0.929 190.87
11 6 240 1.0 50 0.904 195.17
12 10 240 1.0 50 0.948 268.20
13 8 200 0.8 30 0.856 178.90
14 8 280 0.8 30 0.994 265.89
15 8 200 1.2 30 0.944 286.42
16 8 280 1.2 30 0.932 169.16
17 6 240 0.8 30 0.908 192.70
Figure 2. Laser drilling system schematic diagram. 18 10 240 0.8 30 0.916 172.34
19 6 240 1.2 30 0.897 179.60
20 10 240 1.2 30 0.964 273.90
21 8 200 1.0 10 0.932 180.47
22 8 280 1.0 10 0.975 236.41
Table 2. Weight % of composition in Inconel-718. 23 8 200 1.0 50 0.953 175.56
Cr Ni Mo Nb Ti Fe 24 8 280 1.0 50 0.871 177.35
25 8 240 1.0 30 0.898 185.48
17.65 54.25 2.96 4.87 0.72 Remaining 26 8 240 1.0 30 0.896 185.10
27 8 240 1.0 30 0.893 185.94
28 8 240 1.0 30 0.894 185.03
Table 3. Selected Input parameters with their levels. 29 8 240 1.0 30 0.896 185.25

Parameter L1 L2 L3
X1 Assist gas pressure (Bar) 6 8 10
X2 Laser current (Ampere) 200 240 280
X3 Standoff distance (mm) 0.8 1 1.2
X4 Trepanning speed (mm/min.) 10 30 50

been done. Table 3 represents the selected parameters

and levels.

2.2. Input parameters and design for experiments

Where L1, L2, and L3 are the levels of input
parameters.
From the selected input parameters and their respec­
tive levels, 29 experiments are performed according to
BBD (Box-Behnken design). The considered set of
experiments is listed in Table 4. The workpiece
(Inconel −718) with the drilled surface has been shown
in Figure 3. The dimension of the Inconel-718 sheet
taken for the experimentation is 114*114*1.4 mm^3.
Different trepan drilling experiments have been per­
formed on the sheet that has been donated by numbers
as shown in Figure 3. Table 4 also contains the measured
values of responses. The procedure of measuring the Figure 3. Surface views of drilled holes.
responses has been described in the ensuing sub-section.
sample measurement has been shown in Figure 4.
Measurements have been taken with the help of an
2.3. Hole-circularity
optical microscope having maximum 10x magnifica­
In the present work, 29 different holes of diameter tion (LEICA 810; LEICA), available at RRCAT-Indore.
1 mm have been drilled at different combinations of The circularity of the hole has been calculated from
the laser input variable. After conducting the experi­ the diameters using the relations (Dhaker, Singh, and
ments, measurements have been taken on one side of Shrivastava 2019):
each drilled hole. Six diameters d1, d2, d3, d4, d5, and d6
dmin
have been measured along the circumference of all the Hcircularity ¼ (1)
dmax
drilled holes at an interval of 30° angles. One of the
4 K. L. DHAKER ET AL.
Figure 4. Measurements of hole-diameter.
where Hcircularity represents the hole circularity, dmin
represents the minimum diameter and dmax represent
the maximum diameter of the individual holes.
2.4. Recast layer thickness
The recast layer developed due to the re-solidification of
the melted material during drilling. This molten material
re-solidifies due to inappropriate flushing of material.
The recast layer is measured at a scanning electron
microscope (SEM) system (Model No.JSM-6010LA, IIT-
Kanpur, India). Measurements are taken at 4 locations
along the circumference as shown in schematic diagram
Figures 5 and 6. After taking measurements at 4 different
locations (t1, t2, t3, t4) along the circumference of the
drilled hole, the mean value of recasts layer thickness is
calculated every drilled hole by following mathematical
relations (Dhaker, Singh, and Shrivastava 2019):
ðt1 þt2 þt3 þt4 Þ
T ¼ Mean recast layer thickness¼
4 dual parameters is not significant as the p-value of
Figure 5. Scheme of measurement(a) SEM image at ×50 of
one drilled hole with measures diameters (b) SEM of the same
hole at ×160 (c) SEM of the same hole at ×160.
3. Mathematical modelling
Mathematical models are developed with the help of
measured and calculated data by using Response
Surface Methodology (RSM) (Shrivastava and Singh
2018a, 2018b; Box and Draper 1987; Myers,
Montgomery, and Anderson-Cook 2009; Singh and
Nanda 2012, 2013). The mathematical model devel­
oped for circularity and recast layer thickness is given
below.in Equations 3–4.
Circularity ¼ 2:612 0:2003X1 0:00910X2
þ 0:180X3 þ 0:00187X4 þ 0:00317X1 X1
þ 0:000021X2 X2 þ 0:186X3 X3
þ 0:000015X4 X4 þ 0:000519X1 X2
þ 0:0369X1 X3 0:000044X1 X4
(3)
Recastlayer ¼ 1242 þ 82:2X1 þ 6:34X2 þ 458X3
þ 6:92X4 þ 1:96X1 X1 0:00563X2 X2
138X3 X3 0:0334X4 X4
0:4953X1 X2 þ 9:2X1 X3 0:223X1 X4
:133X2 X3 þ 0:01745X2 X4 7:11X3 X4
(4)
where, X1, X2, X3, and X4 represent the input variables
assist gas pressure, laser current, standoff distance, and
trepanning speed, respectively. The analysis of var­
iance (ANOVA) for the developed models has been
shown in Tables 5 and 6. The ANOVA table shows
that the models are significant and the R-square values
obtained for the recast layer and hole-circularity are
86.63% and 84.29%, respectively. These R-square
values also prove that the models are statistically sig­
nificant. From the ANOVA it has also been identified
(2) that in the case of the recast layer, the effect of indivi­
individual parameters is not less than 0.05. However,
in the case of square and two-way interaction para­
meters, X4*X4, X1*X2, X2*X4, and X3*X4 are
significant.
Similarly, in the case of hole circularity, the indivi­
dual parameter X1 is significant. In the case of square
and two-way interaction terms, X2*X2, X1*X2, X2*X3,
and X2*X4 are significant. Moreover, in comparison
to the work carried out by Dhaker et al.(Dhaker and
Pandey 2018; Dhaker, Singh, and Shrivastava 2019)
the same trend had been observed. The individual
parameters reflect very few or non-significant.
However, the interactions are significant.
To identify the error and accuracy of the devel­
oped models, predicted values are calculated using
the equations 3–4 and these predicted values are
compared with values obtained in confirmation
experiments, and comparison is listed in Table 7.
From the comparison Table 7, it is found that the %
 AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 5

Figure 6. (a) SEM image at ×50 of one drilled hole with measures diameters (b, c) SEM of the same hole at ×160.

variation in the value of hole-circularity and recast predicting the response values with appreciable accu­
layer is 8.61% and 12.24%, respectively. The results racy. After developing the mathematical models, the
show that the developed models are capable of genetic algorithm has been adopted to optimise the
6 K. L. DHAKER ET AL.

Table 5. ANOVA for recast layer (R-Sq value 86.63%).

Source DF Adj SS Adj MS F-Value P-Value
Model 14 13,836.9 988.35 6.48 0.001
Linear 4 738.9 184.73 1.21 0.350
X1 1 383.7 383.75 2.52 0.135
X2 1 85.1 85.12 0.56 0.467
X3 1 46.8 46.81 0.31 0.588
X4 1 223.3 223.26 1.46 0.246
Square 4 2428.1 607.03 3.98 0.023
X1*X1 1 399.7 399.67 2.62 0.128
X2*X2 1 525.7 525.75 3.45 0.085
X3*X3 1 198.8 198.75 1.30 0.273
X4*X4 1 1159.6 1159.58 7.60 0.015
2-Way Interaction 6 10,669.8 1778.30 11.66 0.000
X1*X2 1 6280.6 6280.56 41.19 0.000
X1*X3 1 53.7 53.73 0.35 0.562
X1*X4 1 317.6 317.55 2.08 0.171
X2*X3 1 4.5 4.52 0.03 0.866
X2*X4 1 779.8 779.81 5.11 0.040
X3*X4 1 3233.6 3233.63 21.21 0.000
Error 14 2134.9 152.49
Lack-of-Fit 10 2134.3 213.43 1582.75 0.000 Figure 7. Optimal pareto front.
Pure Error 4 0.5 0.13
Total 28 15,971.7
and recast layer have been considered as the objective
function. Different optimisation parameters consid­
Table 6. ANOVA for hole-circularity(R-Sq value 84.29%). ered are;
Source DF Adj SS Adj MS F-Value P-Value Population size: 250;
Model 14 0.028854 0.002061 5.36 0.002 Number of iteration: 600;
Linear 4 0.005855 0.001464 3.81 0.027
X1 1 0.005292 0.005292 13.78 0.002 Crossover probability: 0.8;
X2 1 0.000363 0.000363 0.94 0.348 Mutation probability: 0.8.
X3 1 0.000008 0.000008 0.02 0.885
X4 1 0.000192 0.000192 0.50 0.491
The MOGA optimisation results in 85 optimal sets
Square 4 0.007533 0.001883 4.90 0.011 as shown in the form of the Pareto front in Figure 7.
X1*X1 1 0.001042 0.001042 2.71 0.122
X2*X2 1 0.007247 0.007247 18.86 0.001
Similarly, Figure 8 shows the plot between the average
X3*X3 1 0.000358 0.000358 0.93 0.351 spread and generation. The obtained optimal sets have
X4*X4 1 0.000228 0.000228 0.59 0.454 been plotted in the form of contour as discussed in the
2-Way Interaction 6 0.015466 0.002578 6.71 0.002
X1*X2 1 0.006889 0.006889 17.93 0.001 ensuing section.
X1*X3 1 0.000870 0.000870 2.27 0.155
X1*X4 1 0.000012 0.000012 0.03 0.861
X2*X3 1 0.004225 0.004225 11.00 0.005
X2*X4 1 0.002209 0.002209 5.75 0.031 5. Results and discussion
X3*X4 1 0.001260 0.001260 3.28 0.092
Error 14 0.005378 0.000384 5.1. Effect of input parameters on hole-circularity
Lack-of-Fit 10 0.005363 0.000536 141.14 0.000
Pure Error 4 0.000015 0.000004 To understand the effects of laser input parameters
Total 28 0.034232
on circularity, the obtained optimal solutions have
been drawn in the form of contour plots as shown in
responses and predict an optimal machining range as Figure 9–14. In the contour plot, the red colour
illustrated in the ensuing section. indicates the minimum value of circularity and blue
colour represents the maximum value of circularity,
while the yellow colour represents the intermediate
4. Optimisation of process parameters value. Here, the aim is to maximise the value of
The developed RSM based models are used for finding circularity. Hence, the region of blue colour and
the optimal value of parameters using genetic algo­ yellow colour is the most desired for improved
rithm (GA) (Garg and Tai 2014; Shrivastava and Singh circularity.
2018b, 2018c; Shrivastava and Pandey 2018). The Figure 9(a) represents the dependency of hole-
mathematical models developed for hole-circularity circularity on assist gas pressure and standoff distance.

Table 7. Percentage deviation in some values of Hole-circularity and recast layer.

Predicted value of Hole Percentage deviation in Hole Predicted value of Recast Percentage deviation in Recast
(X1) (X2) (X3) (X4) circularity circularity layer layer
6 280 1.0 30 0.896 8.590 232.10 6.070
10 280 1.0 30 1.021 6.569 141.65 9.238
8 240 0.8 10 0.937 11.681 131.82 14.457
8 240 1.2 50 0.935 11.045 144.37 7.904
8 200 0.8 30 0.904 5.607 165.12 7.703
Average Percentage Deviation 8.61% 12.24%
 AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 7

From the contour plot, it is found that the value of

Figure 8. Plot between average spread and generation.
circularity decreases with the increase in standoff dis­
tance and increases with the decrement in the value of
assist gas pressure. The reason behind that is improper
ejection of melt material from the trepanned hole area.
When the standoff distance is kept low, the high
intensity of laser beam strikes the workpiece and the
time involved in generating through-hole will be less,
hence the molten metal will be flushed at lower air
pressure easily. The higher value of gas pressure
beyond the required value may create force convection
heat losses and turbulence in the drilling zone, which
ultimately results in recast layer formation and higher
difference measured diameter along the circumfer­
ence. Which leads to poor circularity at a higher pres­
sure and higher standoff distance.

Figure 9. Contour plot of hole-circularity (a) between assist gas pressure and standoff distance, (b) between assist gas pressure
and trepanning speed, (c) between assist gas pressure and laser current, (d) between laser current and standoff distance, (e)
between laser current and trepanning speed, (f) between standoff distance and trepanning speed.
8 K. L. DHAKER ET AL.

Figure 10. Contour plots of recast layer thickness (a) between laser current and assist gas pressure, (b) between assist gas pressure
and standoff distance, (c) between assist gas pressure and trepanning speed, (d) between laser current and standoff distance, (e)
between laser current and trepanning speed, (f) between standoff distance and trepanning speed.

flushed out from the drilled surface, resulting in

Figure 11. Measured value of hole diameters at X1 = 8 bar, X2
= 220 amp., X3 = 0.9 mm, and X4 = 10 mm/min.
However, if the standoff distance is kept high,
the time involved in penetrating the through-hole
will be more and the molten material forced to be
poor circularity.
Figure 9(b), represents the effect of assist gas pres­
sure and trepanning speed on circularity. From the
figure, it is observed that, with the increment in the
value of trepanning speed, hole-circularity tends to
decrease. However, a higher value of assist gas pres­
sure is preferable while keeping a lower value of tre­
panning speed. The above phenomenon may be the
result of high machining speed (trepanning speed).
When the machining speed (trepanning speed) is
high the interaction time between the laser beam and
workpiece will be low and the chances of instant
through-hole will be less. Hence, the available molten
material is forced to be flushed from the top surface,
resulting in poor hole circularity. At the higher value
of assist gas pressure along with the lower value of
trepanning speed, proper flushing of molten material

Figure 12. Measured value of the thickness of the recast layer at X1 = 8 bar, X2 = 230 amp., X3 = 0.8 mm, and X4 = 10 mm/min.
Figure 13. Measured value of hole diameters at X1 = 8 bar, X2
= 230 amp., X3 = 0.8 mm, and X4 = 10 mm/min.
happens because of sufficient time available for flush­
ing out.
Figure 9(c) represents the effect of assist gas pressure
and laser current on circularity. From the contour plot,
it is found that the circularity is maximum either at
maximum values of laser current and assist gas pressure
Figure 14. Measured value of the thickness of the recast layer at X1 = 8 bar, X2 = 230 amp., X3 = 0.9 mm, and X4 = 10 mm/min.
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 9
or at the minimum value of both the input parameters.
This can be explained by the fact of proper flushing of
material, as it is clear that with the increase in laser
current make more molten metal available due to
higher heat energy available at the work surface,
which required higher flushing pressure. However, if
the available molten material is less, low flushing pres­
sure is required. Lower assist gas pressure while keeping
laser current at the higher side will yield poor circular­
ity, the fact can be explained as higher laser current
make sure to large heat energy available at the work
surface, which required higher pressure of assist gas to
properly remove molten metal from drilling zone
Figure 9(d) represents the effect of laser current and
standoff distance on circularity. From the contour plot
it has been perceived that at higher value of laser
current while keeping lower standoff distance value,
better hole circularity can be obtained. One of the
reasons for such a trend may be that at a higher laser
current combined with lower standoff distance, the
high intensity of the laser beam will strike the work­
piece. This high power beam will melt the material
more rapidly, hence the time involved in making
a through-hole will be less. Large standoff distance
also responsible for pressure losses of assist gas due
to pressure is exposed to the atmosphere at a higher
value of standoff distance.
10 K. L. DHAKER ET AL.
Figure 9(e) represents the effect of laser current and
trepanning speed on circularity. From the contour plot,
it has been observed that laser current and trepanning
speed have a high impact on hole circularity. If the
value of trepanning speed is kept high and the laser
current is low then there is a chance that instant
through-hole will not be produced and thereby result­
ing in poor hole circularity. Hence, it is recommended
that for good hole circularity, trepanning speed should
not be kept at a higher level. The value of trepanning
speed for getting proper circularity must be kept at
14–15 mm/min. while keeping laser current in the
range of 250–260 amp as indicated in Figure 9(e).
Figure 9(f) shows the variation of hole-circularity
with respect to standoff distance and trepanning
speed. It has been observed that at a lower value of
trepanning speed with lower standoff distance, good
hole circularity can be achieved. The reason that at
higher trepanning speed the interaction time between
the workpiece and laser beam is less. This leads to
a decrease in the possibility of instant through the
hole and hence, indirectly decreases the flushing effi­
ciency, resulting in poor hole circularity(Dhaker,
Singh, and Shrivastava 2019). The lower value of
standoff distance also responsible for the assist gas
pressure is doing its required function of flushing out
the molten metal. The lower value of trepanning and
standoff distance is favourable for proper heating and
proper removal of molten metal, which ultimately
results in a better circularity of drilled hole.
5.2. The dependency of the recast layer on input
parameters
For the understanding of the effect of laser input
parameters on recast layer formation and its thickness,
contour plots from Figure 10(a-f) are developed.
Where red colour represents the minimum value of
the recast layer while the blue colour represents the
maximum value of the recast layer with yellow colour
indicates the in-between value. Here, the aim is to
minimise the value of the recast layer. Hence the
region with red and yellow colour is the most
favourable.
Figure 10(a) shows the dependency of the recast
layer on assist gas pressure and laser current. From the
contour plot, it is clear that the minimum recast layer
thickness can be obtained when the flushing of molten
material is appropriate. More molten material will be
available at the drilling area by increasing laser current
as large heat energy is available and to flush this
material required high air pressure and vice-versa.
However, if appropriate assist gas air pressure is not
available the hole-circularity will be poor. If the mol­
ten material id properly flushed out, this material will
get re-solidified with walls of the drilled hole which
creates large recast layer thickness. Laser current in the
range of 200–210 amp along with lower gas pressure in
the range of 6–7.8 bar is favourable to getting the
reduced thickness of the recast layer as shown in
Figure 10(a).
Figure 10(b) shows the effect of assist gas pressure
and standoff distance.on recast layer thickness. From
these plots, it is found that the recast layer thickness
increases with reducing standoff distance. The focal
length of the laser beam is directly dependent on the
distance of the laser nozzle from the workpiece (stand­
off distance). At higher standoff distance the inap­
propriate focus of the beam will result in excessive
molten material removal from the top of the sheet
resulting in resolidification at the circumference of
the drilled hole and hence the thickness of the recast
layer will be more. Large standoff distance creates
a chance to assist gas pressure to be exposed in the
atmosphere and losses its pressure. Therefore assist
gas pressure in a range of 6 − 7.8 bar while keeping
standoff distance 0.80–0.85 mm is favourable for get­
ting reduced recast layer thickness.
Figure 10(c) shows the effect of assist gas pressure
and trepanning speed on the recast layer. From these
plots, it is concluded that recast layer thickness is
lower while keeping trepanning speed at the lower
side. Interaction time between the laser beam and
workpiece will be large at lower trepanning speed
while large interaction time will be there at lower
trepanning speed. At lower trepanning speed, suffi­
cient time is available for assist gas to remove all the
molten metal from the drilling zone which results in
lower recast layer thickness. Assist gas pressure must
be in the middle of the range 6–10 bar. Gas pressure
behaviour is very complex in laser drilling. Large gas
pressure promotes forced convection heat losses and
lower gas pressure may not be sufficient to remove all
the molten metal generated. Gas pressure should be in
the range of 6.6–7.8 bar while keeping trepanning
speed in the range of 10–12 mm/min is favourable
for getting reduced recast layer thickness.
Figure 10(d) represents the variation in the thick­
ness on the recast layer with respect to the laser cur­
rent and standoff distance. From the contour plot, it
has been noticed that the thickness of the recast layer
is less when the standoff distance is kept at a lower
value. However, the value of laser current can be
varied within this range. This fact can be explained
as, variation in the focal length which is associated
with the standoff distance. At a higher value of stand­
off distance, the laser beam may not be properly
focused, and beam intensity is poor. The improperly
focused beam is not able to sufficiently melt the mate­
rial in a short duration. Improper melting and impro­
per flushing due to assist gas losses its pressure at
higher standoff distance lead to a large thickness of
the recast layer in laser trepan drilling. Laser current in
the range of 252–260 amp while keeping standoff

distance in the range of 0.80–0.82 mm is favourable for
getting reduced recast layer thickness.
Figure 10(e), shows the dependency of the recast
layer on laser current and trepanning speed. It is clear
from the contour plot that, the trepanning speed
should be kept low with intermediate or lower laser
current for minimum recast layer thickness. One of
the possible reasons for such a trend is the interaction
time between the laser beam and the workpiece. If the
interaction time is more i.e. the trepanning speed is
less then the possibility of through-hole is more and
the material will be removed from the bottom surface.
Hence, the chances of molten material resolidification
will be less. As stated earlier laser current effect in
interaction with trepanning speed, at a higher value
of laser current along with the higher value of trepan­
ning speed leads large energy given for a very short
duration of time to the material being heated. At
a higher value of trepanning speed, insufficient flush­
ing of molten metal may occur, which ultimately
results in a higher value of recast layer thickness.
Therefore laser current in the range of 200–210 amp
while keeping trepanning speed in the range of
10–12 mm/min. It is favourable for getting reduced
recast layer thickness.
Figure 10(f) shows the variation in recast layer
thickness with the change in trepanning speed and
standoff distance. From the contour plot, it has been
deduced that trepanning speed and standoff distance
should be set at the minimum level for a lower value of
recast layer thickness. The possible reason for such
a trend is the position of the focal point and material
removal during the process. If the trepanning speed is
high with high standoff distance, less interaction time
between laser beam and workpiece will be available
and the resolidification of molten material will be
more, resulting in large recast layer thickness.
The dependency of responses viz. hole-circularity
and recast layer thickness on different input para­
meters justifies that every input parameter affects the
quality characteristics in laser trepanning operations.
Hence, it is necessary to select the input parameter
properly. To do so, an optimal range of drilling para­
meters is found while considering the interactions of
the contour plots shown in Figure 9(a-f) for hole-
circularity and recast layer, respectively. For calculat­
ing the interaction range. The optimal solutions
obtained from GA has been used. These optimal
Table 8. Interaction range and optimal range of laser input parameters.
For Hole-circularity
X1 X2 X3 X4
Parameters is fixed is fixed is fixed is fixed
X1 6.0–8.4 6.2–8.4 6.0–8.4 - 6.0–9
X2 200–235 200–280 - 200–255
X3 0.8–1.0 - 0.8–0.93 0.8–1.0
X4 - 10–15 10–15 10–15
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 11
solutions have been plotted in the form of contours.
These contour plots have been analysed to identify the
range of the input parameter at which the response is
acceptable. For each response 6 contour plots have
been plotted taking two parameters at a time. For
identification of range, the colour codes have been
used in the region with minimum recast layer thick­
ness has been intersected with the region with max­
imum hole circularity. Hence, the obtained interaction
has been termed as an optimal safe machining range.
This intersection range for hole-circularity and recast
layer has been shown in Table 8. On comparing the
obtained safe machining range with the range of para­
meters identified by Dhaker et al. it has been inferred
that, the safe zone is different than that of the work
reported their work (Dhaker, Singh, and Shrivastava
2019). The range of parameters obtaied in their work
was 7.5–8.5 for assist gas pressure, 240–250 for laser
current, 0.95–1.05 for standoff distance and 25 to 35
for Trepanning speed. However, in that work no opti­
misation of the process has been reported due to
which the obtained hole circularity and recast layer
thickness were not that precise. In comparison to the
reported work. The present work is able to obtain the
more precise drill.
Moreover, to validate the obtained optimal machin­
ing range, more experiments have been performed
and the responses have been measured as shown in
Figure 11–15. The input parameters considered have
been shown in Table 9. Table 9 also contains the
measured values of the responses. From Figures 11
and 13, it is very clear that the values of hole circularity
are increasing with the increase in laser current. As
with the increase in laser current more amount of
material can be removed at the same time. However,
in the case of the recast layer, for experiment 1 the
recast layer is around 154.5 micrometres. While for
experiment 2 it is around 136.2 micrometres. This
sharp decrease in the recast layer shows that the time
involved in through-hole is comparatively less during
experiment 2 when the laser current is 230 amp with
less stand of distance. In the case of increasing the
standoff distance, the rate of materials melting will
below as a result the recast layer will increase. In
Figures 13 and 14 the variation in the recast layer is
very high from 136.2 to 151.8 micrometres. During
both the experimental conditions (2 and 3) all the
parameters are the same except the stand of distance.
For Recast layer Safe machining range
X1 X2 X3 X4
is fixed is fixed is fixed is fixed Optimal
6.2–10 6.0–9.0 - 6.2–8.4
200–280 200–230 - 200–240 200–230
0.8–0.96 - 0.8–0.95 0.8–0.95 0.8–0.93
- 10–15 10–15 10–15 10–15
12 K. L. DHAKER ET AL.

(4) An optimal range of process parameters is

Figure 15. Measured value of hole diameters at X1 = 8 bar,
X2 = 230 amp., X3 = 0.9 mm, and X4 = 10 mm/min.
Table 9. Validation of the obtained range.
Exp. X1 X2 X3 X4 (mm/ Hole- Recast layer
No. (bar) (amp.) (mm) min.) circularity
1. 8 220 0.9 10 0.915
2. 8 230 0.8 10 0.926
3. 8 230 0.9 10 0.916
Hence stand of distance plays a very important role in
controlling the recast layer thickness. From the mea­
sured data for the recast layer and hole-circularity, it
has been observed that the output values are favour­
able and possibly acceptable. Thus, it has been inferred
that the proposed methodology and the obtained opti­
mal machining range are significant.
6. Conclusions
This experimental work aims to predict an optimal range
of process parameters in Nd: YAG laser trepan drilling of
material Inconel-718 sheet. It is found from the analysis
that the mathematical models for circularity and recast
layer are statistically correct. Developed mathematical
models are simultaneously optimised with the help of
genetic algorithm. The obtained optimal solutions have
been plotted in the form of contour. The contour plots
have been analysed to predict the dependency of
responses on input parameters. Finally, by taking the
intersection of the contour plots of circularity and recast
layer thickness. The obtained range of laser drilling input
parameters has been validated by performing more
experiments. The key findings of the present work are;
(1) RSM based modelling is quite suitable for the
laser drilling process
(2) Developed models are significant with an aver­
age % error of 8.61 and 12.24 of circularity and
recast layer thickness respectively.
(3) Genetic algorithm-based multi-objective opti­
misation is suitable for simultaneously improv­
ing conflicting quality characteristics in the
laser drilling process.
found for getting improved hole circularity
and reduced recast layer thickness. Optimal
range found is;
a. The optimal range of assist gas pressure =
6.2–8.4 bar
b. Optimal range of laser current = 200–230
amp
c. Optimal range of standoff distance =
0.8–0.93 mm
d. The optimal range of trepanning speed =
10–15 mm\min.
(5) Methodology and key findings from this work
can be implemented for quality products in the
modern industry. The proposed methodology
can also be helpful in achieving better automa­
tion of the laser drilling process with improved
quality.
(μm)
154.5
136.2 Disclosure statement
151.8
No potential conflict of interest was reported by the authors.
Notes on contributors
Mr. Kedari Lal Dhaker pursued his Bachelor of Engineering
(B. E.) in Mechanical from M.I.T.S. - Gwalior (Government
Aided Autonomous Institute of Madhya Pradesh) - in the
year of 2006. In the year of 2008, he has completed Post
Graduation in Production Engineering from Delhi College
of Engineering (DCE, Delhi University), now Delhi
Technological University (DTU). After completion of Post
Graduation, he has joined the TATA CONSULTING
ENGINEERS LTD (TCE) as trainee Engineer-Mechanical.
Mr. DHAKER has served the TCE for the 5 years and left the
company as Senior Engineer-Mechanical. Having 5 years of
Industrial experience at steel plant project engineering &
equipment design and 5 years of academic & teaching at
JUET. Currently working in University as Assistant
Professor (G-ii)-Mechanical.
Dr. Bhagat Singh has done his graduation in Mechanical
Engineering from NIT, Kurukshetra. He obtained his
Master of Engineering from NIT, Rourkela in Mechanical
Engineering. His specialization in M.Tech was Machine
Design and Vibration Analysis. He was awarded Ph.D.
degree from NIT, Rourkela. The title of his Ph.D. disserta­
tion was -Study of damping in layered and welded beams.”
Dr. Singh has 17 years of teaching and research experience.
He has published 44 papers in peer-reviewed international
journals and conferences proceedings.
Dr. Shrivastava has a result-oriented profile with more than
2 dozens of research papers in various journals of repute. Dr.
Shrivastava has completed his Ph.D. in 2019 with a specia­
lization in manufacturing technology and has research
interest in Fault diagnosis in machinery using signal proces­
sing techniques, Unconventional machining of advanced
materials, Fabrication of fiber reinforced Composite. He
has reviewed many articles that are published in renowned
journals. Currently, he is working as an Assistant Professor
& Research Coordinator in the Department of Mechanical
Engineering at Galgotias College of Engineering and

Technology, Greater Noid, U.P., India.
References
Ahn, D., K. Byun, and M. Kang. 2010. “Thermal
Characteristics in the Cutting of Inconel 718 Superalloy
Using CW Nd: YAG Laser.” Journal of Materials Science
& Technology 26 (4): 362–366. doi:10.1016/S1005-
0302(10)60059-X
Almeida, I., W. De Rossi, M. Lima, J. Berretta, G. Nogueira,
N. Wetter, and V. Jr N. 2006. “Optimization of Titanium
Cutting by Factorial Analysis of the Pulsed Nd: YAG
Laser Parameters.” Journal of Materials Processing
Technology 179 (1–3): 105–110. doi:10.1016/j.
jmatprotec.2006.03.107
Begic-Hajdarevic, D., and I. Bijelonja. 2015. “Experimental
and Numerical Investigation of Temperature
Distribution and Hole Geometry during Laser Drilling
Process.” Procedia Engineering 100: 384–393.
doi:10.1016/j.proeng.2015.01.382
Biscaia, R., M. Ribas, and A. B. Júnior. 2020. “Effects of
Processing Parameters on the Micro-drilling through
Fast Hole Electroerosion and Laser Trepanning in
Inconel 718.” The International Journal of Advanced
Manufacturing Technology. 106 (1–2): 31–45.
doi:10.1007/s00170-019-04394-7
Box, G. E., and N. R. Draper. 1987. Empirical Model-
building and Response Surfaces. Washington, DC: John
Wiley & Sons.
Chien, W.-T., and S.-C. Hou. 2007. “Investigating the Recast
Layer Formed during the Laser Trepan Drilling of Inconel
718 Using the Taguchi Method.” The International Journal
of Advanced Manufacturing Technology. 33 (3–4):
308–316. doi:10.1007/s00170-006-0454-1
Choudhury, I., W. Chong, and G. Vahid. 2012. “Hole
Qualities in Laser Trepanning of Polymeric Materials.”
Optics and Lasers in Engineering 50 (9): 1297–1305.
doi:10.1016/j.optlaseng.2012.02.017
Dhaker, K. L., and A. K. Pandey. 2018. “Experimental Study
of Hole Taper in Laser Trepan Drilling of Nickel Based
Super Alloy Sheet.” Materials Today: Proceedings 5 (11):
23994–24004.
Dhaker, K. L., A. K. Pandey, and B. Upadhayay. 2017.
“Experimental Investigation of Hole Diameter in Laser
Trepan Drilling of Inconel718 Sheet.” Materials Today:
Proceedings 4 (8): 7599–7608.
Dhaker, K. L., B. Singh, and Y. Shrivastava. 2019. “Adaptive
Neuro-fuzzy Inference System Based Modeling of Recast
Layer Thickness during Laser Trepanning of Inconel-718
Sheet.” Journal of the Brazilian Society of Mechanical
Sciences and Engineering 41 (10): 423. doi:10.1007/
s40430-019-1933-2
Duan, W., X. Mei, Z. Fan, J. Chen, and Y. Zhang. 2020.
“Dynamic Change Process of a Recast Layer in Nd: YAG
Millisecond Laser Trepan Drilling.” Journal of the Optical
Society of America B 37 (3): 804–812. doi:10.1364/
JOSAB.380129
Dubey, A. K., and V. Yadava. 2008. “Multi-objective
Optimization of Nd: YAG Laser Cutting of
Nickel-based Superalloy Sheet Using Orthogonal
Array with Principal Component Analysis.” Optics
and Lasers in Engineering 46 (2): 124–132.
doi:10.1016/j.optlaseng.2007.08.011
Garg, A., and K. Tai. 2014. “Stepwise Approach for the
Evolution of Generalized Genetic Programming Model
in Prediction of Surface Finish of the Turning Process.”
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 13
Advances in Engineering Software 78: 16–27. doi:10.1016/
j.advengsoft.2014.08.005
Goyal, R., and A. K. Dubey. 2016. “Modeling and
Optimization of Geometrical Characteristics in Laser
Trepan Drilling of Titanium Alloy.” Journal of
Mechanical Science and Technology 30 (3): 1281–1293.
doi:10.1007/s12206-016-0233-3
Marimuthu, S., M. Antar, J. Dunleavey, D. Chantzis,
W. Darlington, and P. Hayward. 2017. “An
Experimental Study on quasi-CW Fibre Laser Drilling
of Nickel Superalloy.” Optics & Laser Technology 94:
119–127. doi:10.1016/j.optlastec.2017.03.021
Myers, R. H., D. C. Montgomery, and C. M. Anderson-
Cook. 2009. Response Surface Methodology: Process and
Product Optimization Using Designed Experiments (Wiley
Series in Probability and Statistics). New York: Wiley.
Nyon, K., C. Nyeoh, M. Mokhtar, and R. Abdul-Rahman.
2012. “Finite Element Analysis of Laser Inert Gas Cutting
on Inconel 718.” The International Journal of Advanced
Manufacturing Technology 60 (9–12): 995–1007.
doi:10.1007/s00170-011-3655-1
Pandey, A. K., and A. K. Dubey. 2012. “Taguchi Based Fuzzy
Logic Optimization of Multiple Quality Characteristics in
Laser Cutting of Duralumin Sheet.” Optics and Lasers in
Engineering 50 (3): 328–335. doi:10.1016/j.
optlaseng.2011.11.005
Pandey, A. K., and A. K. Dubey. 2013. “Fuzzy Expert System
for Prediction of Kerf Qualities in Pulsed Laser Cutting of
Titanium Alloy Sheet.” Machining Science and Technology
17 (4): 545–574. doi:10.1080/10910344.2013.806182
Rajesh, P., U. Nagaraju, G. H. Gowd, and T. V. Vardhan.
2017. “Experimental and Parametric Studies of Nd: YAG
Laser Drilling on Austenitic Stainless Steel.” The
International Journal of Advanced Manufacturing
Technology 93 (1–4): 65–71. doi:10.1007/s00170-015-
7639-4
Saini, S. K., and A. K. Dubey. 2019. “Study of Material
Characteristics in Laser Trepan Drilling of ZTA.”
Journal of Manufacturing Processes 44: 349–358.
doi:10.1016/j.jmapro.2019.06.017
Sharma, A., and V. Yadava. 2011. “Optimization of Cut
Quality Characteristics during Nd: YAG Laser Straight
Cutting of Ni-based Superalloy Thin Sheet Using Grey
Relational Analysis with Entropy Measurement.”
Materials and Manufacturing Processes 26 (12):
1522–1529. doi:10.1080/10426914.2011.551910
Shrivastava, P. K., and A. K. Pandey. 2018. “Parametric
Optimization of Multiple Quality Characteristics in
Laser Cutting of Inconel-718 by Using Hybrid
Approach of Multiple Regression Analysis and Genetic
Algorithm.” Infrared Physics & Technology 91: 220–232.
doi:10.1016/j.infrared.2018.04.013
Shrivastava, Y., and B. Singh. 2018a. “Estimation of Stable
Cutting Zone in Turning Based on Empirical Mode
Decomposition and Statistical Approach.” Journal of the
Brazilian Society of Mechanical Sciences and Engineering
40 (2): 77. doi:10.1007/s40430-018-0989-8
Shrivastava, Y., and B. Singh. 2018b. “Assessment of Stable
Cutting Zone in CNC Turning Based on Empirical Mode
Decomposition and Genetic Algorithm Approach.”
Proceedings of the Institution of Mechanical Engineers,
Part C: Journal of Mechanical Engineering Science 232
(20): 3573–3594.
Shrivastava, Y., and B. Singh. 2018c. “Stable Cutting Zone
Prediction in CNC Turning Using Adaptive Signal
Processing Technique Merged with Artificial Neural
Network and Multi-objective Genetic Algorithm.”
14 K. L. DHAKER ET AL.
European Journal of Mechanics-A/Solids70: 238–248.
doi:10.1016/j.euromechsol.2018.03.009
Singh, B., and B. Nanda. 2012. “Slip Damping Mechanism in Welded
Structures Using Response Surface Methodology.” Experimental
Mechanics 52 (7): 771–791. doi:10.1007/s11340-011-9563-3
Singh, B., and B. K. Nanda. 2013. “Investigation into the
Effect of Surface Roughness on the Damping of
Tack-welded Structures Using the Response Surface
Methodology Approach.” Journal of Vibration and
Control. 19 (4): 547–559. doi:10.1177/1077546311429056
Tamrin, K., Y. Nukman, I. Choudhury, and S. Shirley. 2015.
“Multiple-objective Optimization in Precision Laser
Cutting of Different Thermoplastics.” Optics and Lasers in
Engineering 67: 57–65. doi:10.1016/j.optlaseng.2014.11.001
Venkatesan, K., R. Ramanujam, and P. Kuppan. 2016.
“Parametric Modeling and Optimization of Laser
Scanning Parameters during Laser Assisted
Machining of Inconel 718.” Optics & Laser
Technology 78: 10–18. doi:10.1016/j.optlastec.2015.0
9.021