Ozkat, Erkan Caner, Franciosa, Pasquale and Ceglarek, Darek (2017) Laser dimpling process parameters selection and optimization using surrogate-driven process capability space. Optics & Laser Technology, 93 . pp. 149-164. doi:10.1016/j.optlastec.2017.02.012

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Abstract

Remote laser welding technology offers opportunities for high production throughput at a competitive cost. However, the remote laser welding process of zinc-coated sheet metal parts in lap joint configuration poses a challenge due to the difference between the melting temperature of the steel (∼1500 C) and the vaporizing temperature of the zinc (~907 C). In fact, the zinc layer at the faying surface is vaporized and the vapour might be trapped within the melting pool leading to weld defects. Various solutions have been proposed to overcome this problem over the years. Among them, laser dimpling has been adopted by manufacturers because of its flexibility and effectiveness along with its cost advantages. In essence, the dimple works as a spacer between the two sheets in lap joint and allows the zinc vapour escape during welding process, thereby preventing weld defects. However, there is a lack of comprehensive characterization of dimpling process for effective implementation in real manufacturing system taking into consideration inherent changes in variability of process parameters. This paper introduces a methodology to develop (i) surrogate model for dimpling process characterization considering multiple–inputs (i.e. key control characteristics) and multiple–outputs (i.e. key performance indicators) system by conducting physical experimentation and using multivariate adaptive regression splines; (ii) process capability space (Cp–Space) based on the developed surrogate model that allows the estimation of a desired process fallout rate in the case of violation of process requirements in the presence of stochastic variation; and, (iii) selection and optimization of the process parameters based on the process capability space. The proposed methodology provides a unique capability to: (i) simulate the effect of process variation as generated by manufacturing process; (ii) model quality requirements with multiple and coupled quality requirements; and (iii) optimize process parameters under competing quality requirements such as maximizing the dimple height while minimizing the dimple lower surface area.

Item Type:	Journal Article
Subjects:	T Technology > TS Manufactures
Divisions:	Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH):	Laser welding, Splines
Journal or Publication Title:	Optics & Laser Technology
Publisher:	Elsevier
ISSN:	0030-3992
Official Date:	1 August 2017
Dates:	Date Event 1 August 2017 Published 9 March 2017 Available 14 February 2017 Accepted 1 September 2016 Submitted
Date of first compliant deposit:	24 April 2017
Volume:	93
Page Range:	pp. 149-164
DOI:	10.1016/j.optlastec.2017.02.012
Status:	Peer Reviewed
Publication Status:	Published
Access rights to Published version:	Open Access
Funder:	Seventh Framework Programme (European Commission) (FP7), Engineering and Physical Sciences Research Council (EPSRC), Turkey. Millî Eğitim Bakanlığı
Grant number:	EU-FP7 FoF-ICT-2011.7.4 (FP7), EP/K019368/1 (EPSRC)
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