Measurement 73 (2015) 596–606

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Measurement
journal homepage: www.elsevier.com/locate/measurement

Optimization of laser cutting parameters for Al6061/SiCp/Al2O3

composite using grey based response surface methodology
(GRSM)
R. Adalarasan a,⇑, M. Santhanakumar a, M. Rajmohan b
a
Department of Mechanical Engineering, Saveetha Engineering College, Chennai, India
b
Department of Industrial Engineering, College of Engineering Guindy, Anna University, Chennai, India

a r t i c l e i n f o a b s t r a c t

Article history: The second generation metal matrix composites (MMCs) find wide applications in
Received 4 June 2014 aerospace and automotive industries. The challenge lies in cutting these advanced
Received in revised form 4 June 2015 materials and obtaining a good surface texture. The present study reports the application
Accepted 9 June 2015
of non-contact type (thermal energy based) pulsed CO2 laser cutting process on
Available online 25 June 2015
Al6061/SiCp/Al2O3 composite. The process parameters in laser cutting influence the kerf
width, surface finish and cut edge slope. These quality characteristics were observed for
Keywords:
the various combinations of cutting parameters like laser power, pulsing frequency, cutting
Laser cutting
Optimization
speed and assist gas pressure. The cutting trials were designed according to Taguchi’s L18
Al6061/SiCp/Al2O3 composite orthogonal array and a hybrid approach of grey based response surface methodology
Grey relational analysis (GRSM) was disclosed for predicting the optimal combination of laser cutting parameters.
Response surface methodology A substantial improvement in the surface finish was observed in the responses obtained
Orthogonal array with the optimal setting of parameters. The atomic force microscopy (AFM) images and
P-profile graphs of the cut surface were also observed to study the surface finish and
texture.
Ó 2015 Elsevier Ltd. All rights reserved.

1. Introduction beam cutting process used for generating complex cut

The first generation of aluminium based composite
materials with ceramic reinforcements are found to exhibit
good strength to weight ratio and better corrosion
resistance. Nowadays, the research attention is focussed
towards the hybrid composites possessing more than one
reinforcing phase. Though aluminium alloys can be cut by
traditional machining processes, the reinforcements in the
hybrid composites create a greater tool wear in conven-
tional cutting [1]. A wide spread application of these second
generation MMCs are not possible without solution to the
problems associated with cutting. The water jet or laser
⇑ Corresponding author. Tel.: +91 9444 108 703.
E-mail addresses: adalarasan@saveetha.ac.in, adalno1@yahoo.co.in
(R. Adalarasan).
profiles also operate on a non-contact mode, however laser
cutting was observed to be faster and cost effective [2,3]. The
material properties including thermal conductivity and
melting point govern the selection of a laser system for
machining [4]. The pulsed CO2 laser beam was used for cut-
ting a wide range of materials including metals, ceramics,
plastics and alumina reinforced composites [5]. The various
stages involved in the mechanism of metal removal by lasers
include melting, vaporizing and degrading. The energy
transfer by irradiation without any cutting force eliminates
the possibility of mechanically induced damage to the work
material [6]. Though a limited investigation was found in
machining aluminium alloys by employing the CO2 lasers,
it is most sought from an industrial perspective [7].
A vast majority of industrial applications involve cut-
ting of metal sheets using lasers because of better finish

http://dx.doi.org/10.1016/j.measurement.2015.06.003
0263-2241/Ó 2015 Elsevier Ltd. All rights reserved.
 R. Adalarasan et al. / Measurement 73 (2015) 596–606
and faster operation [8]. Most polymers could be cut with
good finish using CO2 laser, during which the relationship
between the cutting speed and surface finish was observed
to be non-linear [9]. The high power solid-state fibre lasers
were used to cut titanium alloy sheets with good surface
quality characteristics [10]. The difficult to machine
materials like austenitic stainless steels and Inconel 718
super-alloy sheets could be cut by using a laser beam
assisted by nitrogen or oxygen. It was observed that a
smooth surface with smaller kerf was obtained, while
using nitrogen as an assist gas [11,12]. While cutting steel
sheets, beam waist position was observed to play a signif-
icant role in affecting the kerf width and avoiding the
micro-cracks on the cut surface [13]. From the literature,
it was found that the cutting parameters play a vital role
in deciding the quality characteristics of the cut surface
[9–13].
The multi response optimization problems could be
solved by using methods like grey relational analysis
(GRA), artificial neural network (ANN), genetic algorithm
(GA), response surface methodology (RSM) and fuzzy logic
[14]. The process parameters like beam power, cutting
speed, gas pressure, pulsing frequency and focal point were
investigated in cutting different materials using CO2 laser
beam and optimization was performed effectively using
numerical and statistical techniques [15,16]. However
these techniques do not describe the non-linear relation-
ship between the design variables and responses. Taguchi
based method was employed to study the effects of process
parameters in laser processing and analysis of variance
(ANOVA) was performed to identify the contribution of
various input factors [17,18]. However Taguchi based
arrays used for single response optimization fail to deal
with important interaction effects. The grey theory was
used to find the optimal laser cutting condition for printed
circuit boards and guide plates. The GRA method employs
grey relational grade as a performance index to study the
effects of various cutting parameters [19,20]. The
grey-fuzzy methodology was observed to forecast the bet-
ter cutting condition for duralumin alloy and beam power
was observed to affect the quality characteristics signifi-
cantly [21]. However these fuzzy based techniques are
centred on process knowledge, not easily compatible to
the dynamic changes in cutting processes [22]. An evolu-
tionary approach of genetic programming was utilized to
model the kerf and roughness in laser cutting and the
effect of pulse frequency was observed to be more signifi-
cant than the cutting speed [23]. The approach was refined
by using ANN for forming the models and GA for optimiza-
tion [24]. However difficulty was observed in training the
network and interpreting the non-linear relationship
among various factors, while GA cannot scale well with
the complexity of experimental domain. The Taguchi based
approach using RSM was also applied effectively in
optimizing the multi objectives in laser cutting process
[25,26]. A hybrid approach of grey based PCA was also
found to effectively perform multi response optimization
[27].
The multi response optimization using RSM was charac-
terized by an indefinite saddle function in the quadratic
response surface model. Hence grey relational grade was
597
chosen as the quality index in the disclosed approach of
grey based response surface methodology (GRSM). In
traditional RSM methodology employing the central com-
posite design (CCD) for experimentation, individual math-
ematical models were generated for each of the observed
responses. This restricts the study to observing the effects
of parameters on that particular response alone. Further
the generated response surface plots could be used to
study the parameter effects on those individual responses
only. Hence the study related to simultaneous optimiza-
tion remains restricted in the traditional RSM employing
CCD. The disclosed methodology of GRSM aims at combin-
ing the grey theory with RSM to permit the possibility of
simultaneous optimization of the multiple responses.
Taguchi’s orthogonal array was used for experimentation
to gain the advantage of significant reduction in the num-
ber of cutting trials unlike the CCD. The grey theory was
applied to reduce the variability among the responses
and combine them into grey relational grade, which was
chosen as the representative of responses in the disclosed
approach of GRSM. This combined performance measure
was analysed using RSM, creating the scope for simultane-
ous optimization of the multiple responses.
From the comprehensive review of literature, it was
understood that research work in the area of pulsed CO2
laser cutting of hybrid MMCs was limited. Though the
application of RSM and desirability analysis was existent
in literature, the simultaneous optimization of multiple
quality characteristics in pulsed CO2 laser cutting was
scarce. It was most sought from an industrial perspective
to produce cuts with good quality characteristics like min-
imal kerf width, good surface finish and lesser edge slope
angle. Hence the work was focussed towards predicting
the optimal cutting condition for Al6061/SiCp/Al2O3
composites using a hybrid approach of grey based RSM.
2. Experimental design and observation
2.1. Material and machine setup
The work material used in the study was
Al6061/SiC/Al2O3 composite. The Al6061 aluminium alloy
was used as the matrix phase for the second generation
composite material. The reinforcing particles of silicon car-
bide (SiC) and alumina (Al2O3) were added in weight frac-
tion of 10% each and dispersed in the liquid matrix phase
using the process of two stage stir casting. Two cast sheets
of dimension 12 cm  12 cm  4 mm each were subjected
to radiographic testing to validate the absence of defects.
The cutting experiments are performed in pulsed CO2 laser
cutting machine using nitrogen as the assist gas, whose
discharge is formed between two RF excited electrodes.
The laser beam was focussed to a spot diameter of
0.2 mm by using a lens of focal length 127 mm. The laser
machine could operate with a maximum beam power of
3.8 KW and a PLC based system was employed for varying
the speed of cutting and pulsing frequency. The laser beam
impact angle was kept at 90° during all the trials and the
nozzle-workpiece stand-off distance was maintained at
1 mm during various trials.
598 R. Adalarasan et al. / Measurement 73 (2015) 596–606
2.2. Experimentation
The quality characteristics of the cut surface depends on
dominant process parameters like the laser beam power (A),
cutting velocity (B), gas pressure (C) and pulsing frequency
(D) [9–13,15–17,18,20,21]. However the focal point was not
considered in this investigation as a cutting parameter. The
pilot cutting trials were performed to reduce the allowable
range of process parameters and to sort out the acceptable
upper and lower bounds of parameters, for which cut sur-
face quality remained decent with lesser heat affected zone
and minimum dross. The process parameters were varied at
three levels and Taguchi’s L18 orthogonal array (OA) was
used to conduct the cutting trials. Two (replicates) square
specimens of dimension 20 mm  20 mm  4 mm were
cut during various trials and the experiments were per-
formed at random order to reduce the effects of extraneous
factors [14]. The schematic layout of the process indicating
the principle of laser cutting is shown in Fig. 1(a). A uniform
distance was ensured between the square profiles cut dur-
ing each trial in a single pass and a button-hole cut was also
made in each specimen for measuring the kerf width. The
measured quality characteristics include the surface rough-
ness (SR), kerf width (KW) and cut edge slope (ES, angle h)
(Fig. 1(b)). The kerf indicates the loss of material and rough-
ness represents the surface texture. The first six specimens
cut during the trials are shown in Fig. 1(c).
The Surfcoder-SE3500 (contact stylus surface roughness
tester) was used to measure the surface roughness. The
roughness measurements were taken at the middle of
depth (2 mm) on all four cut sides along the direction of
cut. The centre-line average surface roughness (Ra) values
were acquired for a cut-off length of 0.8 mm. The cut edge
slope and kerf width were measured using a video measur-
ing system (Model: VMS-2010F). It was equipped with a
high resolution CCD colour camera, multifunctional digital
readout and RS-232 interface. The maximum possible
magnification with the VMS-2010F system was 190X. The
kerf width was measured as the mean of top and bottom
kerf from the button-hole cut made in each specimen.
The scheme of measurement of KW and ES (angle ‘h’) is
shown in Fig 1(b). The combination of parameters during
various cutting trials and the quality characteristics (aver-
age response of two replicated cutting trials) obtained are
shown in Table 1.
3. Multi response optimization using grey based
response surface methodology (GRSM)
The multi response optimization is an offline quality
control technique offering a practical solution to the
demand for good surface finish in cut edges. Taguchi
techniques use the signal-to-noise (S/N) ratio instead of
standard deviation to compare the responses and the usage
of orthogonal arrays reduce the number of experimental
trials. The grey theory analysis compensates the drawback
of regression analysis by identifying the relationship
between elements based on the amount of difference or
similarity of trends among those elements [28]. The grey
relational grade calculated using the grey theory is used
as a quality representative of all the responses, which
was further modelled using the method of RSM furnishing
the scope for simultaneous optimization of the responses.
The technique of grey based response surface methodology
(GRSM) is disclosed in two phases.
3.1. Phase I: Grey relational analysis
Step 1: Calculate the S/N ratio (yij) for the observed
responses using the lower-the-better criterion
from Eq. (1). The lower-the-better analysis tends
to minimize the responses thereby enhancing
the quality characteristics observed in the pro-
cess [19,28,29].
!
  1 Xn
 2
S=N Ratio gij ¼ 10log10  y ð1Þ
r i¼1 ij k
where yij is the observed response value; r is the number
of replications; n is the number of responses; m is the
number of observations; k = 1,2, . . ., r; j = 1,2, . . ., m.
Step 2: Compute the normalized S/N ratio (Zij) using Eq.
(2), to avoid the variability effect among the S/N
ratio [27,28]. The value of normalized S/N ratio
lies between 0 and 1.
yij  minðyij ; i ¼ 1; 2; . . . ; mÞ
Z ij ¼
maxðyij ; i ¼ 1; 2; . . . ; mÞ  minðyij ; i ¼ 1; 2; . . . ; mÞ
ð2Þ
Step 3: Compute the grey relational coefficient (GRC (c))
using Eq. (3), to express the relationship
between the observed and actual normalized
experimental results [19].
D min þnD max
cij ¼ ð3Þ
Doj ðiÞ þ nD max
 
where Doj ¼ zo ðiÞ  zj ðiÞ; zo ðiÞ is the referential sequence;
zj ðiÞ is the comparative sequence; D min ¼ min min kzo ðiÞ
 
8j2i 8i
zj ðiÞk and D max ¼ max max zo ðiÞ  zj ðiÞ. n is the distin-
8j2i 8i
guishing coefficient whose value is chosen to magnify the
noteworthy difference between the relational coefficients.
Step 4: Find the average of GRC values using Eq. (4), to
find the grey relational grade (GRG). The GRG
is taken as the single representative for the mul-
tiple responses [28].
1X n
GRGj ¼ cj ð4Þ
n i¼1 i
3.2. Phase II: Response surface methodology
The response surface methodology is a dynamic tool
which maps the relationship between the design variables
and responses for achieving either maximization or
minimization of the quality characteristics. The complexity
increases with the number of quality characteristics
observed during experimentation [25]. Hence the GRG rep-
resenting the multiple responses is taken as a single perfor-
mance and is used in the generation of response surfaces.
 R. Adalarasan et al. / Measurement 73 (2015) 596–606 599

(a)

(b)

Buttonhole cut

(c)

Fig. 1. (a) Schematic layout of the process, (b) measurement of kerf width and edge slope angle and (c) first six specimens cut during the trials.

Step 5: Establish the mathematical model for the GRG. It
is a polynomial regression equation of second
order (quadratic model) generated to clarify
the behaviour within the system domain [26].
Step 6: Perform the analysis of variance (ANOVA) with
GRG values. The ANOVA was performed to sup-
plement the GRSM method and to identify the
contribution of different parameters in affecting
the responses.
Step 7: Generate the response surfaces to study the
effects of different parameter levels on the
GRG.
Step 8: Determine the optimal laser cutting condition
using the desirability analysis.
600 R. Adalarasan et al. / Measurement 73 (2015) 596–606

Table 1
Quality characteristics observed during the various cutting trials.

Trial Input parameters Responses

A (W) B (mm/s) C (MPa) D (Hz) SR (lm) KW (mm) ES (°)
1 2000 10 0.8 8 4.722 0.333 2.093
2 2000 20 1 10 3.546 0.328 2.107
3 2000 30 1.2 12 2.635 0.323 2.296
4 2500 10 0.8 10 4.492 0.320 2.091
5 2500 20 1 12 3.213 0.356 1.969
6 2500 30 1.2 8 3.192 0.325 2.242
7 3000 10 1 8 3.031 0.398 1.813
8 3000 20 1.2 10 2.509 0.326 1.902
9 3000 30 0.8 12 2.231 0.331 2.169
10 2000 10 1.2 12 3.323 0.324 1.993
11 2000 20 0.8 8 4.587 0.363 2.123
12 2000 30 0.8 10 3.871 0.315 2.206
13 2500 10 1 12 4.385 0.334 1.908
14 2500 20 1.2 8 3.933 0.336 2.199
15 2500 30 0.8 10 4.347 0.317 2.256
16 3000 10 1.2 10 3.385 0.329 1.786
17 3000 20 0.8 12 2.482 0.376 1.933
18 3000 30 1 8 3.012 0.355 1.825

Step 9: Conduct the confirmation experiment for vali- responses and a higher value of GRG is desired regardless
dating the optimal parameter setting. of the nature of the experimental responses. The GRG val-
ues plotted for the different experimental trials are shown
in Fig. 2. The peak value of GRG was observed for the six-
4. Results and discussion teenth trial, indicating the closeness of the operating con-
dition to the optimum parameter setting.
4.1. Grey relational generation

The grey generating technique was applied to transform
the disordered raw experimental data into a regular series
to measure the relationship between different elements
[28]. All the observed responses were treated as the
lower-the-better characteristics with a target value of zero.
A linear normalization was performed on the observed
responses and the GRG values are listed in Table 2. The
GRG values offer the single representation for the three
4.2. Mathematical model for GRG
The RSM methodology employs a mathematical proce-
dure to map the decision variables with the responses
and form a polynomial equation of second order (quadratic
model). The generated mathematical model quantifies the
association and explores the individual and interaction
effects of cutting parameters on the responses, hence

Table 2
Calculated values of GRC and GRG for the various experimental trials.

Trial S/N ratio Normalized S/N ratio GRC GRG

SR KW ES SR KW ES SR KW ES
1 13.483 9.561 6.415 0.000 0.772 0.369 0.250 0.594 0.345 0.3962
2 10.995 9.677 6.473 0.382 0.829 0.342 0.350 0.661 0.336 0.4490
3 8.416 9.826 7.219 0.778 0.903 0.000 0.600 0.774 0.250 0.5414
4 13.049 9.904 6.407 0.067 0.942 0.372 0.263 0.851 0.347 0.4868
5 10.138 8.977 5.885 0.514 0.483 0.612 0.406 0.392 0.462 0.4200
6 10.081 9.761 7.013 0.522 0.871 0.095 0.411 0.720 0.269 0.4667
7 9.632 7.999 5.168 0.591 0.000 0.940 0.449 0.250 0.848 0.5156
8 7.990 9.742 5.584 0.843 0.861 0.749 0.680 0.706 0.571 0.6523
9 6.970 9.617 6.725 1.000 0.799 0.227 1.000 0.624 0.301 0.6417
10 10.431 9.776 5.990 0.469 0.878 0.563 0.385 0.732 0.433 0.5168
11 13.231 8.811 6.539 0.039 0.401 0.312 0.257 0.357 0.326 0.3136
12 11.756 10.022 6.872 0.265 1.000 0.159 0.312 1.000 0.284 0.5318
13 12.839 9.520 5.612 0.099 0.752 0.737 0.270 0.573 0.559 0.4672
14 11.894 9.485 6.845 0.244 0.734 0.172 0.306 0.556 0.287 0.3829
15 12.764 9.969 7.067 0.110 0.973 0.070 0.272 0.926 0.264 0.4874
16 10.591 9.659 5.038 0.444 0.821 1.000 0.375 0.650 1.000 0.6748
17 7.896 8.494 5.725 0.858 0.245 0.685 0.701 0.306 0.514 0.5069
18 9.577 8.986 5.225 0.600 0.488 0.914 0.454 0.394 0.795 0.5477
 R. Adalarasan et al. / Measurement 73 (2015) 596–606 601

Peak value of GRG

0.7

0.65

0.6

0.55

GRG 0.5

0.45

0.4

0.35

0.3
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Trials

Fig. 2. Variation of GRG values during different trials.

Table 3
Results of ANOVA.

Source Sum of squares DOF Mean square F-value p-value Prob > F
Model 0.1454 10 0.0145 35.2611 <0.0001 Significant
A-Laser power 0.0025 1 0.0025 5.9478 0.0448
B-Cutting velocity 0.0031 1 0.0031 7.5807 0.0284
C-Gas pressure 0.0025 1 0.0025 6.0405 0.0436
D-Pulsing frequency 0.0502 1 0.0502 121.7958 <0.0001
AC 0.0284 1 0.0284 68.7481 <0.0001
AD 0.0122 1 0.0122 29.6802 0.0010
BD 0.0196 1 0.0196 47.4918 0.0002
CD 0.0348 1 0.0348 84.3979 <0.0001
A2 0.0208 1 0.0208 50.5514 0.0002
B2 0.0198 1 0.0198 48.0536 0.0002
C2 0.0029 7 0.0004
Residual 0.1483 17
Cor total 0.1454 10 0.0145 35.2611 <0.0001 Significant

offering the scope to study the behaviour of system
[25,26]. Taguchi’s L18 OA was used for experimental design,
which was a relatively different approach compared to the
CCD employed with RSM. The gain was a considerable
decrease in the number of experimental trials. A mathe-
matical model was developed for the response surface to
explain the effect of laser cutting parameters on the GRG.
The model coefficients were formulated using the Design
Expert software (version 7.0.0) and the precise quadratic
model was disclosed in Eq. (5), after excluding the insignif-
icant terms (model reduction).
GRG ¼ 3:31490  3:33712  103  A  0:031482  B
 5:67350  C þ 0:81763  D þ 1:68385  103  A  C
 1:3297  104  A  D  0:42051  C  D
þ 5:83390  107  A2 þ 8:33640  104  B2
þ 2:75129  C 2
4.3. Model fitness and adequacy verification
The analysis of variance (ANOVA) was carried out to
find the adequacy of quadratic model and hence determine
the importance of coefficients and model fitness in
establishing a scientific link between the observed quality
characteristics and the cutting parameters. From the
results of ANOVA (Table 3), the generated quadratic model
for GRG was observed to be significant and it was proved
by the model F-value (35.2611). The probability of a larger
F-value due to the uncontrollable noise factors was
observed to be less (0.01%). The influence of different terms
in the model was proved by the lesser probability value.
Hence the ANOVA results had disclosed the importance
of model terms A, B, C, D, the interaction terms AC, AD,
CD and second order of factors A, B and C. The developed
model for GRG was further improved by eliminating the
insignificant terms. The ANOVA results had proved the
capability of generated model (Eq. (5)) in representing
the cutting conditions in CO2 laser cutting process.
The R-squared and adequate precision values were
sorted out using the design expert software. The
ð5Þ R-squared value for the model was observed to be 0.9805
(close to unity), indicating a better fit between the mathe-
matical model and the actual data observed within the
experimental domain. The predicted and adjusted
R-squared values were in reasonable agreement with each
other proving the fitness of experimental data to the gen-
erated model. The value of adequate precision (22.8469)
was considerably larger than 4.0, attesting the required
602 R. Adalarasan et al. / Measurement 73 (2015) 596–606

model discrimination. Hence the generated mathematical
model displaying the higher values of determination
coefficient and adequate precision could be deemed fit to
predict the GRG values.
4.4. Study of response surfaces
The aluminium alloys were difficult to cut by lasers due
to their high reflectivity and thermal conductivity. The
problem was further intensified by the self-extinguishing
oxidation reaction and a higher power requirement in con-
tinuous wave mode of operation [16]. Hence a pulsed laser
beam using nitrogen as the process gas was employed to
cut with a better laser coupling. The response surface plots
(Fig. 3) were drawn based on the generated polynomial
equation (Eq. (5)) associating the dependent variable GRG
with the independent variables such as laser power, gas
pressure, cutting velocity and pulsing frequency. Three
response surface plots were generated and displayed,
avoiding the interaction plot with insignificant effect.
Generally a higher degree of melting was found at the
top surface of the work material than at the bottom
surface. A lower level of pulse frequency was desired
(Fig. 3a and b) to improve the value of GRG and hence
the responses. This is due to the fact that high instanta-
neous energy in pulses at high frequency results in melting
and re-solidification, affecting the finish of the cut surface.
The use of nitrogen as assist gas at high gas pressure leads
to easy ejection of molten metal, minimizing the dross
(Fig. 3c). The purging out of dross at higher gas pressure
reduces the kerf width and surface roughness improving
the value of GRG [13]. The effective ejection of molten
metal by high pressure gas also reduces the cut edge slope.
A higher level of laser power (Fig. 3a and b) was found to
increase the energy content of the beam which is utmost
essential in melting the matrix. The assist gas pressure
removes a portion of reinforcements along with it, while
some portion of the reinforcements requires more thermal
energy for vaporizing them. However higher energy of
laser at lower cutting speed can cause thermal damage to
the cut surface, while a higher cutting speed causes
striations and spoils the finish. Hence a moderate level
(19.94 mm/s) of cutting speed is desired while taking cuts
for better kerf and finish.

4.5. Desirability analysis

The desirability function can be of three type viz.

larger-the-better, smaller-the-better and nominal-the-better.
The desirability analysis was performed on the calculated
GRG values using the larger-the-better desirability function
and the operating condition producing the maximum value
of desirability was chosen as optimal cutting condition
(Table 4). The optimal level of cutting parameters was
identified as: laser power = 2970.94 W, cutting veloc-
ity = 19.94 mm/s, gas pressure = 1.20 MPa and pulsing
frequency = 8.42 Hz.
The values of desirability indicating the preferred level
of various cutting parameters is shown in the ramp

Table 4
Selection of the optimal level of laser cutting parameters.

Symbol Parameter Optimal Low High

value level level
A Laser power (W) 2970.94 2000 3000
B Cutting velocity 19.94 10 30
(mm/s)
C Gas pressure 1.20 0.8 1.2
(MPa)
D Pulsing frequency 8.42 8 12
(Hz)
Fig. 3. Response surface plots depicting the effects of parameter inter- Response Prediction SE mean 95% CI 95% CI
actions on GRG (a) effect of pulsing frequency and gas pressure, (b) effect low high
of laser power and pulsing frequency and (c) effect of gas pressure and GRG 0.7138 0.0328 0.6363 0.7914
laser power.
 R. Adalarasan et al. / Measurement 73 (2015) 596–606 603

Fig. 4. Ramp function graph of desirability.

function graph (Fig. 4). The desirable level was shown by a
dot on each ramp and the height of dot indicates the
amount of desirability. The optimal value was positioned
at the top rising part of the graph representing a desirabil-
ity value of 1.00 and confirming a significant degree of
proximity between the target data and responses. The plot
showing the actual and predicted values of GRG prove the
degree of proximity (Fig. 5). Most of the values fall close to
a straight line indicating normal distribution of errors.
Hence the prediction can be regarded as reliable.
The optimal value of laser power was obtained as
2970.94 W. A higher level of laser power could increase
the energy content of the beam to melt and vaporize both
the matrix and reinforcement phases. However the
thermal damage to the cut surface could be severe at lower
values of cutting velocities, while a higher velocity
increases the striations in cut surface. Hence a moderate
cutting velocity of 19.94 mm/s was obtained as the optimal
level from desirability analysis. A higher value of pulse
frequency could cause overlapping and re-solidification,
spoiling the surface finish. Hence a lower level of pulsing
frequency (8.42 Hz) was chosen as the optimal level. A
higher level of gas pressure (1.2 MPa) was chosen as the
optimal level for easy and effective ejection of molten
metal reducing the cut edge slope.
A severe non-uniform temperature gradient near the
cut surface results in an undesired residual stress distribu-
tion, which becomes prominent while handling thicker
sheets using lasers. This could lead to development and
propagation of micro cracks reducing the component’s fati-
gue life. The selection of an optimal level of processing
parameters could reduce the stress fields. However further
investigation was required to study the distribution of
residual stresses and maintain the stress fields within tol-
erable levels.
4.6. Confirmation experiment
A confirmation test becomes essential to validate the
hybrid approach of GRSM employed for optimization. The
parameter combination (Trial 16) for which the experi-
mental responses yielded the maximum value of GRG
(0.6748) was chosen as the initial parameter setting. The
quality characteristics observed for the initial parameter
setting were compared with those obtained with the opti-
mal parameter setting, predicted by the GRSM method
(Table 5). It was found that the GRSM approach had
improved the quality characteristics significantly.
The surface finish of the cut surface was important in
assessing the quality of a machined component. The func-
tional attributes of the components made of MMCs in

Table 5
Responses obtained with the initial parameter setting and GRSM setting.

Parameter GRG Responses

settings
Surface Kerf Edge
roughness width slope (°)
(lm) (mm)
Initial setting 0.6748 3.385 0.328 1.699
Optimal setting 0.7138 2.781 0.337 1.538
using GRSM
Improvement 0.0390 0.604 0.009 0.161
% Improvement 5.78% 17.84% 2.74% 9.48%
Fig. 5. Plot of the actual versus predicted GRG values.
604 R. Adalarasan et al. / Measurement 73 (2015) 596–606

Fig. 6. P-profile graph and AFM image showing surface finish and texture for (a) initial setting and (b) optimal setting of parameters.
 R. Adalarasan et al. / Measurement 73 (2015) 596–606
aerospace and automotive applications demand character-
istics such as wear resistance, heat dissipation and
lubricant holding capabilities, which depend heavily on
the surface roughness. A good surface finish could avoid
further processing reducing the cost and time as well. An
improvement of 17.84% was observed in surface finish of
the cut surface obtained with the GRSM setting. The cut
surfaces obtained with initial setting of parameter and
the GRSM setting is shown in Fig. 6. A considerable reduc-
tion in striations was observed with the surface cut with
optimal parameter setting. The P-profile plots were also
displayed to demonstrate the improvement in surface
finish obtained with optimal setting of parameters.
The atomic force microscopy images show an enhanced
texture of the cut surface obtained with the GRSM setting.
The improved texture was indicated by the lesser
variations in the contrast as visualized from the Fig. 6b.
4. Conclusion
The pulsed CO2 laser cutting is a multi-input process
requiring the optimization of multiple responses. From
the review of literature, it was understood that the
application of RSM remains limited in multi response
optimization problems. Hence in this present work,
Al6061/SiC/Al2O3 sheets of thickness 4 mm were cut using
the pulsed CO2 laser cutting process and a hybrid approach
of grey based response surface methodology (GRSM) was
disclosed to predict the optimal level of cutting parame-
ters. Taguchi’s L18 OA was used to design the experimental
trials and the following conclusions were drawn.
 The hybrid technique of GRSM was found to be ade-
quate, fit and effective in predicting the optimal setting
of laser cutting parameters for Al6061/SiC/Al2O3
composite (laser power = 2970.94 W, cutting veloc-
ity = 19.94 mm/s, gas pressure = 1.20 MPa and pulsing
frequency = 8.42 Hz).
 The predicted values of grey relational grade and the
experimentally obtained values matched reasonably
well demonstrating a better model fitness.
 The parameters investigated in the laser cutting process
(laser power, cutting velocity, gas pressure and pulsing
frequency) were found to be significant in influencing
the responses represented by GRG. The generated
response surface model was found to be sufficient and
substantial in establishing the relationship among
various cutting parameters.
 The GRA was applied to form the single representative
(GRG) for the three quality characteristics studied in
laser cutting and RSM approach was used to create a
model for GRG. Thus the uncertainty handling abilities
of grey theory was combined with the modelling capa-
bilities of RSM, permitting the application of GRSM for
multi response optimization in manufacturing
industries.
The generated response surface model along with the
investigation findings will offer the necessary database
and guidelines for cutting Al6061/SiC/Al2O3 composite
sheets using pulsed CO2 laser cutting process. This will
605
widen the scope of automotive and aerospace applications
of these second generation MMCs.
Acknowledgements
The authors would like to extend their thanks to Rohini
Weldtech Pvt. Ltd., Chennai and Nanotechnology Centre,
Anna University, Chennai for extending their facility and
guidance to carry out the research work.
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