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OPTICSLASERTECHNOLOGY40OFINSTITUTE1LOSSSPEEDKEYWORDSTAGUCHIMETHOD；LASERBEAMCUTTING；HYBRIDAPPROACHINDUSTRIESTOACHIEVECOMPLEXSHAPES/PROFILESWITHCLOSEMETHODINWHICHSHEETMATERIALISCUTMAINLYDUETOMELTINGANDVAPORISATIONTHEMOLTENMATERIALISEJECTEDWITHTHEHELPOFHIGHPRESSUREASSISTGASJET4THESCHEMATICOFTHEINMOSTOFTHEEXPERIMENTALINVESTIGATIONSOFTHELBCRESEARCHERSHAVEINCORPORATEDDESIGNOFEXPERIMENTSMETHODOLOGIESSUCHASTHERESPONSESURFACEMETHODOLOGYRSMANDTAGUCHIMETHODOLOGYTMDURINGEXPERIARTICLEINPRESSMENTALSTUDYOFLBCPROCESSTAMETAL11APPLIEDTHETAGUCHIMETHODTOSTUDYTHELASERCUTTINGPROCESSFOR45MMTHICKMILDSTEELSHEETTHE00303992/SEEFRONTMATTERR2007ELSEVIERLTDALLRIGHTSRESERVEDDOI101016/JOPTLASTEC200709002C3CORRESPONDINGAUTHORTEL915322271812；FAX915322445101EMAILADDRESSAVANISHDUBEYYAHOOCOMAKUMARDUBEYTOLERANCESFORCUTTINGOFSTEELSHEETS3THEMOSTWIDELYUSEDINDUSTRIALLASERSFORCUTTINGOFSHEETMETALSAREGASEOUSCO2ANDSOLIDSTATENDYAGTHEREHASBEENGROWINGINTERESTINRECENTYEARSINTHEUSEOFPULSEDNDYAGLASERSFORPRECISIONCUTTINGOFTHINSHEETMETALSBECAUSEOFITSHIGHINTENSITY,LOWMEANBEAMPOWER,GOODFOCUSINGCHARACTERISTICS,ANDNARROWHEATAFFECTEDZONEHAZLBCISATHERMALENERGYBASEDNONCONVENTIONALCUTTINGPROCESS,RESEARCHERSHAVEVARIEDONEFACTORATATIMETOANALYSETHEEFFECTOFINPUTPROCESSPARAMETERSONOUTPUTQUALITYCHARACTERISTICSORRESPONSES5–10BUTTHISTECHNIQUEREQUIRESALARGENUMBEROFEXPERIMENTALRUNSBECAUSEONLYONEFACTORISVARIEDINEACHRUN,KEEPINGALLOTHERFACTORSCONSTANTALSO,INTHISTECHNIQUE,THEINTERACTIONEFFECTSAMONGVARIOUSINPUTPROCESSPARAMETERSARENOTCONSIDEREDTOOVERCOMETHESEPROBLEMS,SOME1INTRODUCTIONTHELASERWASINVENTEDIN1960SANDHASWIDEAPPLICATIONSINTHEFIELDOFFINECUTTINGOFSHEETMETALSDUETOITSPRECISIONANDHIGHINTENSITY1,2LASERBEAMCUTTINGLBCCANBESUCCESSFULLYUSEDFORTHECUTTINGOFCONDUCTIVEANDNONCONDUCTIVEDIFFICULTTOCUTADVANCEDENGINEERINGMATERIALSSUCHASREFLECTIVEMETALS,PLASTICS,RUBBERS,CERAMICSANDCOMPOSITESAPARTFROMCUTTINGDIFFICULTTOCUTMATERIALS,LBCISMOSTWIDELYUSEDINLBCPROCESSHASBEENSHOWNINFIG1SINCEITSINTRODUCTION,LBCHASALWAYSBEENAMAJORRESEARCHAREAFORGETTINGTHEEXCEPTIONALLYGOODQUALITYOFCUTTHEQUALITYOFCUTSOLELYDEPENDSONTHESETTINGOFPROCESSPARAMETERSSUCHASLASERPOWER,TYPEANDPRESSUREOFASSISTGAS,SHEETMATERIALTHICKNESSANDITSCOMPOSITION,CUTTINGSPEED,ANDMODEOFOPERATIONCONTINUOUSWAVEORPULSEDMODEALOTOFEXPERIMENTALINVESTIGATIONHASBEENUNDERTAKENWITHTHEAIMOFANALYSINGTHEEFFECTOFPROCESSPARAMETERSONCUTGEOMETRY,ANDCUTSURFACEQUALITYMULTIOBJECTIVEOPTIMISATIONAVANISHKUMARDUBEYDEPARTMENTOFMECHANICALENGINEERING,MOTILALNEHRUNATIONALRECEIVED31JULY2007；RECEIVEDINREVISEDFORMABSTRACTTHISPAPERPRESENTSAHYBRIDTAGUCHIMETHODANDRESPONSESURFACEBEAMCUTTINGPROCESSTHEAPPROACHFIRSTUSESTHETAGUCHIQUALITYSUCHASASSISTGASPRESSURE,PULSEWIDTH,PULSEFREQUENCYANDCUTTINGCENTRALVALUESINTHERESPONSESURFACEMETHODTODEVELOPANDOPTIMISEKERFWIDTHKW,ANDMATERIALREMOVALRATEMRR,THATAREOFDIFFERENTTHEHIGHERTHEBETTERTYPE,HAVEBEENSELECTEDFORSIMULTANEOUSOPTIMISATIONQUALITYCHARACTERISTICSWHENTHEHYBRIDAPPROACHISUSED,ASCOMPAREDR2007ELSEVIERLTDALLRIGHTSRESERVED2008562–570LASERBEAMCUTTINGPROCESSC3,VINODYADAVAOFTECHNOLOGY,TELIARGANJ,ALLAHABAD,UP211004,INDIASEPTEMBER2007；ACCEPTED7SEPTEMBER2007METHODTMRSMFORTHEMULTIRESPONSEOPTIMISATIONOFALASERFUNCTIONTOFINDTHEOPTIMUMLEVELOFINPUTCUTTINGPARAMETERSTHEOPTIMUMINPUTPARAMETERVALUESAREFURTHERUSEDASTHETHESECONDORDERRESPONSEMODELTHETWOQUALITYCHARACTERISTICSNATUREKWISOFTHESMALLERTHEBETTERTYPE,WHILEMRRISOFTHERESULTSSHOWCONSIDERABLEIMPROVEMENTINBOTHTHETHERESULTSOFASINGLEAPPROACHWWWELSEVIERCOM/LOCATE/OPTLASTECARTICLEINPRESSNOMENCLATUREBREGRESSIONCOEFFICIENTDCOMPOSITEDESIRABILITYDINDIVIDUALDESIRABILITYKNUMBEROFRESPONSESORQUALITYCHARACTERISTICSLIJTHEQUALITYLOSSFORTHEITHQUALITYCHARACTERISTICATTHEJTHTRIALCONDITIONORRUNLIMAXIMUMQUALITYLOSSFORTHEITHQUALITYCHARACTERISTICAMONGALLTHEEXPERIMENTALRUNSMMEANOFMULTIPLES/NRATIOSOFALLEXPERIMENTALRUNSNNUMBEROFEXPERIMENTALRUNSPNUMBEROFCONTROLFACTORSORINPUTPROCESSPARAMETERSAKUMARDUBEY,VYADAVA/OPTICSLASERSIGNALTONOISES/NRATIOOFOVERALLFIGUREOFMERITWASCONSIDEREDASQUALITYFUNCTIONTHISQUALITYFUNCTIONINTEGRATESTHEWEIGHTEDEFFECTSOFQUALITYCHARACTERISTICSKERFWIDTHKW,SURFACEROUGHNESS,MICROHARDNESS,SLOPEOFCUTEDGEANDHAZANDCOSTCOMPONENTSCUTTINGSPEED,OXYGENPRESSUREANDBEAMPOWERLIMETAL12HAVEAPPLIEDTHESAMEAPPROACHFORTHESTUDYOFTHESURFACEROUGHNESSOBTAINEDDURINGHIGHSPEEDLASERCUTTINGOFSTAINLESSSTEELSHEETSLIETAL13HAVEALSOAPPLIEDTAGUCHI’SROBUSTDESIGNMETHODOLOGYTOSTUDYTHEWIDTHOFCUTANDHAZDURINGLASERCUTTINGOFQUADFLATNOQFNLEADPACKAGESUSINGADIODEPUMPEDSOLIDSTATELASERDPSSLSYSTEMTHECUTTINGPARAMETERSTAKENARELASERCURRENT,LASERFREQUENCYANDCUTTINGSPEEDMATHEWETAL14PERFORMEDPARAMETRICSTUDIESONPULSEDNDYAGLASERCUTTINGOFFIBREREINFORCEDPLASTICCOMPOSITESHEET2MMTHICKACENTRALCOMPOSITEDESIGNCCDWITHUNIFORMPRECISIONWASUSEDFOREXPERIMENTALDESIGNANDASECONDORDERRESPONSESURFACEMODELFORHAZGASJETDRAGLINESMELTINGORSLAGNOZZLEGASFOCUSINGOPTICSLASERBEAMCUTTINGEDGEONWORKPIECEFIG1SCHEMATICOFLASERBEAMCUTTINGANDKERFTAPERWASDEVELOPEDTHEINPUTPROCESSPARAMETERSWERECUTTINGSPEED,PULSEENERGY,PULSEDURATION,PULSEREPETITIONRATEANDGASPRESSUREALMEIDAETAL15APPLIEDFACTORIALDESIGNAPPROACHTODETERMINETHEEFFECTSOFPULSEENERGY,OVERLAPPINGRATEANDTYPEOFASSISTGASONTHESURFACEROUGHNESSANDDROSSFORMATIONEDGEIRREGULARITYDURINGNDYAGLASERCUTTINGOFPURETITANIUMANDTITANIUMALLOYTI6AL4VTHEDESIGNOFEXPERIMENTSBASEDSTUDIESONLBCPROCESSSOFARHAVEBEENMAINLYAIMEDATTHEOPTIMISATIONOFTHESINGLEQUALITYCHARACTERISTICATATIMEITHASBEENFOUNDTHATTHEOPTIMUMPARAMETERSETTINGSFORONEQUALITYCHARACTERISTICMAYDETERIORATEOTHERQUALITYCHARACTERISTICSASTHEAIMOFAMANUFACTURINGPROCESSISALWAYSTOIMPROVETHEOVERALLQUALITYOFAPRODUCTITISNECESSARYTOOPTIMISETHEMULTIPLEQUALITYCHARACTERISTICSSIMULTANEOUSLYANTONY16HASDEMONSTRATEDATAGUCHIQUALITYLOSSFUNCTIONBASEDMULTIOBJECTIVEOPTIMISATIONTECHNIQUEFORMANUFACTURINGPROCESSESTAKINGANEXAMPLEOFELECTROWIWEIGHTINGFACTORASSIGNEDTOITHRESPONSEORQUALITYCHARACTERISTICXIITHINPUTPROCESSPARAMETERORCONTROLFACTORYJTOTALNORMALISEDQUALITYLOSSVALUEINJTHEXPERIMENTALRUNYIRESPONSEOROBSERVEDQUALITYVALUEINITHEXPERIMENTALRUNYIJNORMALISEDQUALITYLOSSVALUEFORITHEXPERIMENTALRUNANDJTHQUALITYCHARACTERISTICZS/NRATIOZOPREDICTEDMULTIPLES/NRATIOATOPTIMUMPARAMETERLEVELSZEJMULTIPLES/NRATIOOFJTHTRIALCONDITIONOREXPERIMENTALRUNTECHNOLOGY402008562–570563NICASSEMBLYPROBLEMHEHASFOUNDCONSIDERABLEIMPROVEMENTINMULTIPLEQUALITYCHARACTERISTICS,INCOMPARISONTOSINGLEQUALITYCHARACTERISTICSDIFFERENTHYBRIDAPPROACHESHAVERECENTLYBEENUSEDFORTHEOPTIMISATIONOFDIFFERENTMACHININGPROCESSESTAGUCHIMETHODWITHFUZZYLOGIC17ORWITHGREYRELATIONALANALYSIS18HASBEENUSEDTOOPTIMISETHEELECTRICALDISCHARGEMACHININGPROCESSANONCONVENTIONALTHERMALBASEDMACHININGPROCESSWITHMULTIPLEMACHININGPERFORMANCECHIADAMRONG19HASSUGGESTEDASEQUENTIALINTEGRATIONAPPROACHOFTMANDRSMTOOPTIMISETHEQUALITYCHARACTERISTICSINMANUFACTURINGSYSTEMHEDEMONSTRATEDTHEHYBRIDMETHODOLOGYBYTAKINGACASESTUDYOFPRINTEDCIRCUITBOARDMANUFACTURINGPLANTANDFOUNDASIGNIFICANTREDUCTIONINQUALITYLOSSTHEHYBRIDAPPROACHOFTMANDRSMHASYETNOTBEENAPPLIEDINTHESTUDYOFLBCPROCESSWITHSINGLEORMULTIPLEPERFORMANCEMEASURESINTHEPRESENTPAPERAHYBRIDTAGUCHIMETHODANDRESPONSESURFACEMETHODTMRSMAPPROACHHASBEENUSEDTODEVELOPTHERESPONSEMODELSANDTOOPTIMISETHESELECTIONOFOAISBASEDONTHETOTALDEGREEOFFREEDOMDOFOFARTICLEINPRESSLASERTHEPROCESSMATHEMATICALLY,THEDOFCANBECOMPUTEDAS22DOFNUMBEROFLEVELSC01FOREACHCONTROLFACTORNUMBEROFLEVELSFORAC01C2NUMBEROFLEVELSFORBC01FOREACHINTERACTION1C138,1WHERE,AANDBARETHEINTERACTINGCONTROLFACTORSINTHETAGUCHIMETHOD,THES/NRATIOZISUSEDTOREPRESENTTHEQUALITYCHARACTERISTICSFORTHEOBSERVEDDATAORRESPONSESHERE,THE‘SIGNAL’REPRESENTSTHEDESIRABLEVALUEANDTHE‘NOISE’REPRESENTSTHEUNDESIRABLEVALUEANDS/NRATIOEXPRESSESTHESCATTERAROUNDTHEDESIREDVALUETHELARGERTHES/NRATIO,SMALLERWILLBETHESCATTERDEPENDINGONTHEEXPERIMENTALOBJECTIVES,THEREARESEVERALQUALITYCHARACTERISTICSINTHEPRESENTCASE,ASMALLERVALUEOFKWANDAHIGHERVALUEOFMRRAREDESIRABLEINTHETAGUCHIMETHODTHESECHARACTERISTICSARETERMEDSBTYPEANDHBTYPERESPECTIVELYMATHEMATICALLY,THES/NRATIOSZFORSBANDHBTYPEQUALITYCHARACTERISTICSCANBECOMPUTEDAS21–22LBCPROCESSFORMULTIPLEQUALITYCHARACTERISTICSSUCHASKW,ANDMATERIALREMOVALRATEMRRAPULSEDNDYAGLASERBEAMISUSEDFORCUTTINGOFTHINSHEETSOFMAGNETICMATERIALGRAINORIENTEDHIGHSILICONALLOYSTEELSHEETSUSEDINTRANSFORMERSTHEQUALITYCHARACTERISTICSOFTWODIFFERENTNATUREKWISOFSMALLERTHEBETTERSBTYPEANDMRRISOFHIGHERTHEBETTERHBTYPEWITHUNEQUALWEIGHTINGFACTORKW80,ANDMRR20HAVEBEENSELECTEDFIRSTLY,TMISAPPLIEDTODETERMINETHEOPTIMUMPROCESSPARAMETERSFORMULTIPLEQUALITYCHARACTERISTICSIEFORMINIMUMKWANDMAXIMUMMRRTHEOUTPUTOPTIMUMPARAMETERVALUESFROMTMISFURTHERUSEDASCENTRALVALUEINRSMTHESECONDORDERRESPONSEMODELFORKWANDMRRHASBEENDEVELOPEDBYPERFORMINGTHEEXPERIMENTSUSINGTHECENTRALCOMPOSITEROTATABLEDESIGNCCRDMATRIX20THEMINITABSOFTWAREHASBEENUSEDTOCALCULATETHEFINALRESULTSOFMULTIOBJECTIVEOPTIMISATIONTHERESULTSOFMULTIOBJECTIVEOPTIMISATIONUSINGTAGUCHI’SQUALITYLOSSFUNCTIONONLYHAVEALSOBEENCOMPAREDWITHTHERESULTSFROMHYBRIDAPPROACH2EXPERIMENTALPLANNINGMETHODS21TAGUCHIMETHODINTHETAGUCHIMETHOD,THEOPTIMUMLEVELOFINPUTPROCESSPARAMETERSORCONTROLFACTORSAREDECIDEDONTHEBASISOFSTATISTICALANALYSISOFEXPERIMENTALRESULTSTHATMAKESTHEPROCESSINSENSITIVETOTHEEFFECTOFVARIATIONSDUETOUNCONTROLLABLEORNOISEFACTORSSUCHASENVIRONMENTALTEMPERATURE,HUMIDITYANDVIBRATIONINTHISMETHOD,THEEXPERIMENTSAREPERFORMEDASPERSPECIALLYDESIGNEDEXPERIMENTALMATRIXKNOWNASORTHOGONALARRAYOA21–22THEAKUMARDUBEY,VYADAVA/OPTICS564ZC010LOG10MSD,2WHERE,MSDMEANSQUAREDEVIATIONFROMTHEDESIREDVALUEANDCOMMONLYKNOWNASQUALITYLOSSFUNCTIONFORSBC0TYPE；MSD1NXNI1Y2I,3FORHBC0TYPE；MSD1NXNI11Y2I,4WHERE,YIISTHEOBSERVEDRESPONSEORQUALITYVALUEATTHEITHTRIALOREXPERIMENTALRUNANDNISTHENUMBEROFTRIALSATSAMEPARAMETERLEVELINMULTIOBJECTIVEOPTIMISATION,ASINGLEOVERALLS/NRATIOFORALLQUALITYCHARACTERISTICSISCOMPUTEDINPLACEOFSEPARATES/NRATIOSFOREACHOFTHEQUALITYCHARACTERISTICTHISOVERALLS/NRATIOISKNOWNWITHTHENAMEOFMULTIPLES/NRATIOMSNRTHEMSNRFORJTHTRIALZEJISCOMPUTEDASGIVENBELOW16ZEJC010LOG10YJ,5YJXKI1WIYIJ,6YIJLIJLIC3,7WHEREYJISTHETOTALNORMALISEDQUALITYLOSSINJTHTRIAL,WIREPRESENTSTHEWEIGHTINGFACTORFORTHEITHQUALITYCHARACTERISTIC,KISTHETOTALNUMBEROFQUALITYCHARACTERISTICSANDYIJISTHENORMALISEDQUALITYLOSSASSOCIATEDWITHTHEITHQUALITYCHARACTER