A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics
This study explores through transmission laser welding of dissimilar, optically transparent polymers, acrylic and polycarbonates using a novel hybrid approach that integrates Response Surface Methodology (RSM) and Finite Element Method (FEM). Quantitative analysis involved a 3 factor, 3 level centra...
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| Format: | Article |
| Language: | English |
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IOP Publishing
2024-01-01
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| Series: | Materials Research Express |
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| Online Access: | https://doi.org/10.1088/2053-1591/ad95e3 |
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| author | Nitesh Kumar Soumyabrata Chakravarty Nikhil Kumar Rajat Subhra Sen |
| author_facet | Nitesh Kumar Soumyabrata Chakravarty Nikhil Kumar Rajat Subhra Sen |
| author_sort | Nitesh Kumar |
| collection | DOAJ |
| description | This study explores through transmission laser welding of dissimilar, optically transparent polymers, acrylic and polycarbonates using a novel hybrid approach that integrates Response Surface Methodology (RSM) and Finite Element Method (FEM). Quantitative analysis involved a 3 factor, 3 level central composite design with process inputs of laser power, frequency and scanning speed. The resulting weld qualities, such as weld width, Heat Affected Zone (HAZ), ware measured, showing weld width ranges from 112.65 μm to 302.64 μm and HAZ between 20.85 μm to 105 μm. The thermal modelling provided predictions for depth of penetration, with values spanning from 106.25 μm to 228.65 μm. validated against experimental data, demonstrating an average error of 8.09%. Qualitatively, the investigation indicatees that laser power and scanning speed substantially effect the weld quality, with higher power leading to broader weld widths and greater HAZ. The FEM simulations confirmed these trends and provided insights into temperature distributions. The investigation contributes to the existing knowledge pool that would be beneficial to the academia and industries. |
| format | Article |
| id | doaj-art-2cb7ecb939084e8a85d61b073b66308d |
| institution | OA Journals |
| issn | 2053-1591 |
| language | English |
| publishDate | 2024-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | Materials Research Express |
| spelling | doaj-art-2cb7ecb939084e8a85d61b073b66308d2025-08-20T01:54:30ZengIOP PublishingMaterials Research Express2053-15912024-01-01111111531010.1088/2053-1591/ad95e3A combined RSM – FEM analysis of weld quality in laser transmission welding of plasticsNitesh Kumar0Soumyabrata Chakravarty1https://orcid.org/0000-0002-3579-9161Nikhil Kumar2https://orcid.org/0009-0007-3873-6477Rajat Subhra Sen3Mechanical Engineering Department, Jadavpur University , Kolkata 700032, West Bengal, India; Mechanical Engineering Department, Brainware University , Kolkata 700125, West Bengal, IndiaMechanical Engineering Department, Jadavpur University , Kolkata 700032, West Bengal, India; Mechanical Engineering Department, Brainware University , Kolkata 700125, West Bengal, IndiaWMG, The University of Warwick , Coventry CV4 7AL, United KingdomMechanical Engineering Department, Jadavpur University , Kolkata 700032, West Bengal, IndiaThis study explores through transmission laser welding of dissimilar, optically transparent polymers, acrylic and polycarbonates using a novel hybrid approach that integrates Response Surface Methodology (RSM) and Finite Element Method (FEM). Quantitative analysis involved a 3 factor, 3 level central composite design with process inputs of laser power, frequency and scanning speed. The resulting weld qualities, such as weld width, Heat Affected Zone (HAZ), ware measured, showing weld width ranges from 112.65 μm to 302.64 μm and HAZ between 20.85 μm to 105 μm. The thermal modelling provided predictions for depth of penetration, with values spanning from 106.25 μm to 228.65 μm. validated against experimental data, demonstrating an average error of 8.09%. Qualitatively, the investigation indicatees that laser power and scanning speed substantially effect the weld quality, with higher power leading to broader weld widths and greater HAZ. The FEM simulations confirmed these trends and provided insights into temperature distributions. The investigation contributes to the existing knowledge pool that would be beneficial to the academia and industries.https://doi.org/10.1088/2053-1591/ad95e3laser transmission weldingsimulationweld qualitytransparent plasticsdepth of penetration |
| spellingShingle | Nitesh Kumar Soumyabrata Chakravarty Nikhil Kumar Rajat Subhra Sen A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics Materials Research Express laser transmission welding simulation weld quality transparent plastics depth of penetration |
| title | A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics |
| title_full | A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics |
| title_fullStr | A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics |
| title_full_unstemmed | A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics |
| title_short | A combined RSM – FEM analysis of weld quality in laser transmission welding of plastics |
| title_sort | combined rsm fem analysis of weld quality in laser transmission welding of plastics |
| topic | laser transmission welding simulation weld quality transparent plastics depth of penetration |
| url | https://doi.org/10.1088/2053-1591/ad95e3 |
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