Developing Laser-Assisted Machining Process for Nickel based Superalloy IN625 Using Experimental and Statistical Analysis

This study evaluated the optimization of process parameters in laser-assisted turning of IN625 nickel-based superalloy. IN625 is renowned for its high-temperature strength and work-hardening properties, making it challenging to machine using traditional techniques. In order to overcome this difficulty, a laser-assisted machining setup was employed that combined a conventional lathe with a 6 kW fibre-coupled diode laser and dynamometer. The Box-Behnken design of experiments strategy based on Response Surface Methodology was used to optimize the machining conditions. The interplay between various machining properties, such as cutting forces, flank wear, and surface roughness, and machining process parameters, such as laser power, spindle speed, feed rate, and depth of cut, was investigated. The optimal parameters for laser-assisted turning of IN625 alloy included a laser power of 625 W, speed of 45 m/min, and feed of 0.15 mm/rev. These parameters led to reductions in cutting forces of 20% (F x ), 17% (F y ), 30% (F z ), as well as maximum flank wear and surface roughness of 18% and 16%, respectively. This study provides an effective strategy for optimizing the machining of IN625 alloys, which is difficult to machine by traditional techniques due to its high-temperature strength and work-hardening properties.