materials

Article
The Effect of Laser Parameters on Cutting
Metallic Materials
Seungik Son 1 and Dongkyoung Lee 1,2, *
1 Department of Future Convergence Engineering, Kongju National University, Cheonan 1223-24, Korea;
[email protected]
2 Department of Mechanical and Automotive Engineering, Kongju National University,
Cheonan 1223-24, Korea
* Correspondence: [email protected]; Tel.: +82-41-521-9260; Fax: +82-41-555-9123




Received: 13 September 2020; Accepted: 14 October 2020; Published: 15 October 2020


Abstract: This experimental study investigated the effect of laser parameters on the machining of
SS41 and SUS304. The metallic materials play an important role in engineering applications. They are
widely used in high-tech industries such as aerospace, automotive, and architecture. Due to the
development of technology and high-tech industrialization, the various processing technologies are
being developed with the requirement of high precision. However, the conventional cutting process
is difficult to meet high precision processing. Therefore, to achieve high precision processing of the
SS41 and SUS304, laser manufacturing has been applied. The current study investigated the process
quality of laser cutting for SS41 and SUS304, with the usage of a continuous wave CO2 laser cutting
system. The experimental variables are set to the laser cutting speed, laser power, and different
engineering materials. The results are significantly affected by the laser parameters. As the result,
the process quality of the laser cutting has been observed by measuring the top and bottom kerf
widths, as well as the size of the melting zone and Heat Affected Zone (HAZ) according to volume
energy. In addition, the evaluation of the laser processing parameters is significantly important to
achieve optimal cutting quality. Therefore, we observed the correlation between the laser parameters
and cutting quality. These were evaluated by analysis of variance (ANOVA) and multiple regression
analysis. The experimental results of kerf top, kerf bottom, melting width, and HAZ on the laser
parameters are properly predicted by multiple regression. In addition, the effect of laser parameters
on the materials is determinant by the percentage of contribution of ANOVA.

Keywords: high-power laser cutting; laser parameters; cutting quality; ANOVA; multiple regression

1. Introduction
There are various metallic materials used for production in the industrial fields. Among the
metallic materials commonly used in industry, SS41 and SUS304 are the most widely used. SS41 is a
structural steel containing Si and Mn. It is widely used in various fields such as aerospace, automobiles,
ships, and construction due to its great mechanical properties and low cost. SUS304 is stainless
steel that has high corrosion resistance due to containing Cr component. It is generally used for
various applications without surface treatment because the metallic materials have low thermal
deformation. It is challenging to machine SS41 and SUS304 with high precision using conventional
techniques such as mechanical cutting, drilling milling. The features of the mechanical method
have critical processing problems such as tools wearing [1]. However, the limitation of mechanical
processing can be solved by laser processing. Thus, the laser machining using CO2 laser is used as an
alternative to the conventional method. Furthermore, the manufacturer prefers to use high-power laser
processing rather than mechanical processing because the laser processing has more advantages than

Materials 2020, 13, 4596; doi:10.3390/ma13204596 www.mdpi.com/journal/materials

Materials 2020, 13, 4596 2 of 15

mechanical processing. Laser machining can be performed on various materials without tool wear and
additional cost. The method is non-contact processing, which provides flexibility in processing [2–15].
Among the laser system used by industries, the CO2 laser has more economical than other laser
systems. In addition, the laser system has high stability during the cutting or drilling processes of the
significantly thick materials. Even non-metallic materials can be easily processed using a CO2 laser.
The special concern for manufacturers using laser cutting is to maximize productivity with the high
quality of components produced through the high-power laser cutting process. However, to improve
product quality and productivity, the effects of laser parameters on the material should be considered
as major issues. In addition, to control the influence of the laser beam, the laser parameters must
be selected appropriately. Indeed, adjustable laser parameters include laser power, cutting speed,
assist gas pressure, and stand-off distance.
To maintain high precision and good quality process, the laser parameters applied to the
process should be properly selected, but the effect of the parameters is difficult to predict. Besides,
many manufacturers spend a lot of time and effort to determine the laser parameter which suitable for the
process. In the previous studies, experiments were carried out according to specific laser parameters,
and there was a comparative analysis of the effect of each parameter on the processing quality.
Lamikiz et al. [16] suggested the optimum working areas and cutting conditions for the laser cutting
of steel. The main experimental parameter was the thickness of the material and the results showed
a remarkable different behavior between the thinnest and the thickest sheets. Kaebernick et al. [17]
described a monitoring technique in the laser cutting. The analytical techniques proved that the
surface roughness was improved by controlling laser pulses. Rajaram et al. [18] studied the effect
of parameters on the characteristics of steel specimens. The material was cut through a CO2 laser
cutting system and cutting results were analyzed with kerf width, surface roughness, and heat-affected
zone. The material which was cut using the CO2 laser showed different results depending on the
change of parameters. Yilbas [19] suggested that various parameters were affected during the laser
cutting process and then, the laser power and the cutting speed for the kerf width were examined. It
was confirmed that the kerf width increased with the combination of the laser power and the energy
coupling factor. Anghel et al. [20] demonstrated the experiment of laser cutting on 304 stainless steel
miniature gear. In the experiment, the CO2 laser system was employed to cut the miniature. The effects
of laser parameters on average surface roughness (Ra ) had been investigated on the surface of craters
and cracks.
The previous studies have done significant investigations on the influence of laser parameters in
the laser cutting process to materials. However, there is a lack of experimental studies on comparing
laser cutting of SS41 and SUS304 under different laser parameters. In this study, we studied the effect
of high-power laser parameters on the different metallic materials. Multiple regression and analysis of
variance (ANOVA) are used to predict the kerf width, melting width, and Heat Affected Zones (HAZ)
generated after laser cutting. In addition, these are used to investigate the effects of parameter and
interaction between parameters. In this paper, we firstly describe the material properties, experimental
equipment, and laser parameters. Then, the experimental results are discussed. Finally, conclusions
are summarized.

2. Experimental Setup and Materials

In the present study, a continuous wavelength CO2 laser system, which has a maximum laser
power of 4.4 kW (Bylaser 4400, Bystronic, Niederönz, Switzerland), was used for the cutting process.
During the experiment, the stand-off distance of the laser is set to constant, and the spot diameter
is fixed at 2 mm. In addition, the laser cutting process depends on assistance gases. The assistance
gases, N2 and O2 , are common assistance gasses used for laser cutting on stainless steel or carbon
steel [21,22]. When cutting with O2 gas, in the case of SS41, it is easily heated up to vaporizing
temperature, thus, the material is also easily cut by a laser beam. In addition, when the SUS304 is
processed using N2 gas, the oxidation can be protected during laser cutting. At the cutting process of
Materials 2020, 13, 4596 3 of 15

the SS41 and SUS304, the assistance gases are used by the constant pressure of O2 and N2 , respectively,
to maintain high processing quality. Table 1 shows the laser parameters applied to SS41 and SUS304.
Materials 2020, 13, x FOR PEER REVIEW 3 of 16
Different laser powers and cutting speeds were conducted to cut the materials in the experiment.
The laser parameters
parameters are setare set range
in the in thewhere
rangethe
where the material
material was completely
was completely cut. Table 2 cut.
shows Table 2 shows the
the chemical
chemical composition of the materials used in the experiment. In order to analyze the
composition of the materials used in the experiment. In order to analyze the experimental results, the experimental
results, the
kerf kerf generated
widths widths generated after the
after the cutting cutting
process process are
are measured measured
on both top andon both surfaces
bottom top and[23].
bottom
surfaces [23]. In addition,
In addition, melting
melting width width
and Heat and Heat Zone
Affected Affected Zone
(HAZ) (HAZ)
formed in formed in the
the bottom bottom
surface surface
of the
materials are measured using an optical microscope (Dino-lite AM4013MZT4,
of the materials are measured using an optical microscope (Dino-lite AM4013MZT4, AnMo Electronics AnMo Electronics
Corporation,
Corporation, NewNew Taipei,
Taipei, Taiwan).
Taiwan). The
The schematics of
schematics of the
the kerf
kerfwidths,
widths,melting
meltingwidth,
width,andand
HAZ are are
HAZ
shown in Figure 1. The kerf widths are the part where the laser is irradiated,
shown in Figure 1. The kerf widths are the part where the laser is irradiated, and the material and the material is is
completely cut-off. The kerf widths are measured in the kerf top and kerf bottom. The melting width
completely cut-off. The kerf widths are measured in the kerf top and kerf bottom. The melting width
is defined by the width of the materials with melting marks as in Figure 1 HAZ is the region where
is defined by the width of the materials with melting marks as in Figure 1 HAZ is the region where the
the microstructure of the materials has changed.
microstructure of the materials has changed.
Table 1. Laser parameters.
Table 1. Laser parameters.
SS41 SUS304
SS41 SUS304
Laser Power [W] 1000–3700 2100–3900
Laser Power [W] 1000–3700 2100–3900
Cutting Speed [mm/s] 2000–4100 2000–3500
Cutting Speed [mm/s] 2000–4100 2000–3500
Assistance
Assistance Gas Gas OO22 N2 N2
Gas Pressure [bar]
Gas Pressure [bar] 33 3 3
Thickness [mm] 2 2
Thickness [mm] 2 2

Table Materials
2. 2.
Table Materialschemical
chemical composition.
composition.

C C SiSi Mn
Mn PP SS NiNi CrCr
SS41SS41
Properties
Properties 0.14~0.22 ≤0.3
[%][%] 0.14~0.22 ≤0.3 0.36~0.65
0.36~0.65 ≤≤0.045
0.045 ≤0.05
≤0.05
SUS304 Properties [%] 0.08 1.00 2.00 0.45 0.30 8.00~10.50 18.00~20.00
SUS304Properties [%] 0.08 1.00 2.00 0.45 0.30 8.00~10.50 18.00~20.00

Figure 1. Measurement method of SS41 and SUS304 after laser cutting (a) top surface (b) bottom surface
Figure 1. Measurement method of SS41 and SUS304 after laser cutting (a) top surface (b) bottom
(c) topsurface
surface(c)(d)
topbottom
surface surface.
(d) bottom surface.
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3. 3.
Results and
Results Discussion
and Discussion
3.1. Analysis of Kerf Width in SS41 According to Volume Energy
3.1. Analysis of Kerf Width in SS41 According to Volume Energy
The experimental results of laser cutting on metallic materials (SS41 and SUS304) are investigated.
The experimental results of laser cutting on metallic materials (SS41 and SUS304) are
The kerf width of the top and bottom surface, melting width, and HAZ are analyzed according to
investigated. The kerf width of the top and bottom surface, melting width, and HAZ are analyzed
volume energy. Volume energy is also an important parameter in the laser cutting process which is
according to volume energy. Volume energy is also an important parameter in the laser cutting
used to understand the interaction between laser and materials [24]. The volume energy (Evolume ) is a
process which is used to understand the interaction between laser and materials [24]. The volume
parameter that represents the irradiated laser per unit volume, and it is calculated by the laser power
energy (E ) is a parameter that represents the irradiated laser per unit volume, and it is calculated
divided by the laser scanning speed and the laser beam size.
by the laser power divided by the laser scanning speed and the laser beam size.
P
E = =laser J/m (J/m3 ,),
 
Evolume (1)
(1)
Vs × A∗
where, P is the laser power [W], V is the cutting speed [mm/min], and A is the spot area of the
where Plaserlaser
is the laser power [W], Vs is sthe cutting speed [mm/min], and A is the spot area of the
laser beam [mm]. Experimental results are analyzed through Evolume to identify the effect on the laser
laser beam [mm]. Experimental results are analyzed through Evolume to identify the effect on the laser
powers and cutting speed.
powers and cutting speed.
The effect of E on the kerf widths of the top and bottom surface is shown in Figure 2. The
The effect of Evolume on the kerf widths of the top and bottom surface is shown in Figure 2.
measurements of the kerf widths are conducted on both top and bottom sections of the cutting
The measurements of the kerf widths are conducted on both top and bottom sections of the cutting
material. Each data point represents the different laser power and is obtained by averaging all
material. Each data point represents the different laser power and is obtained by averaging all measured
measured data. The kerf widths of the top and bottom surface increase with increasing E .
data. The kerf widths of the top and bottom surface increase with increasing Evolume . Generally,
Generally, the measured kerf widths on the top surface are slightly larger than those on the bottom
the measured kerf widths on the top surface are slightly larger than those on the bottom surface.
surface. This happens due to various reasons, such as loss of intensity of the beam, defocusing of the
This happens due to various reasons, such as loss of intensity of the beam, defocusing of the laser
laser beam, or loss of gas pressure. In addition, the kerf widths of the top and bottom surface increase
beam, or loss of gas pressure. In addition, the kerf widths of the top and bottom surface increase with
with increasing laser power. At the laser power of 3700 W, the kerf widths of the top and bottom
increasing laser power. At the laser power of 3700 W, the kerf widths of the top and bottom surface
surface are observed with the largest widths of 905 μm and 675 μm, respectively. In the interaction
are observed with the largest widths of 905 µm and 675 µm, respectively. In the interaction between
between laser and materials, it is evident that kerf widths are affected by E . As the E
laser and materials, it is evident that kerf widths are affected by Evolume . As the Evolume increases,
increases, the material is rapidly heated. In addition, the materials are evaporated and removed easily
the material is rapidly heated. In addition, the materials are evaporated and removed easily on the
on the top surface. Therefore, a larger kerf width of the top surface is formed than the kerf width of
top surface. Therefore, a larger kerf width of the top surface is formed than the kerf width of the
the bottom surface.
bottom surface.

(a)

Figure 2. Cont.
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Materials 2020, 13, x FOR PEER REVIEW 5 of 16
Materials 2020, 13, 4596 5 of 15

(b)
(b)
Figure 2. Variation of (a) kerf and (b) kerf in SS41 according to E .
Figure
Figure 2. 2.Variation
Variationofof
(a)(a) kerf
kerf and
top and (b)(b) kerf
kerf bottom in in SS41
SS41 according
according E .
tovolume
to E .
3.2. Analysis of Melting Width in SS41 According to Volume Energy
3.2. Analysis
3.2. Analysis of of
Melting
Melting Width
Widthin in
SS41
SS41According
According to to
Volume
Volume Energy
Energy
The effect of E on the melting width of the bottom surface is shown in Figure 3. Each
TheTheeffect of Eof
effect E on the
volume onmelting width of
the melting the bottom
width of the surface
bottomissurface
shown in is Figure
shown 3.inEach measured
Figure 3. melts
Each
measured data is obtained by averaging melting width. Melting is the area where the material
data is obtained
measured data by
is averaging
obtained melting
by width.
averaging Melting
melting is
width. the area
Melting where
is thethe material
area where melts
the due
material to melts
the
due to the laser irradiation, and melting occurs around the kerf width. At most of the laser powers
laser
dueirradiation,
to the and melting occurs around occurs
the kerfaround
width. theAt most of the laser powers applied in the
applied in laser irradiation,
the experiment, and melting
melting width increases kerf width.
with increasing E At most. At of
thethe laser
laser powers
power of
experiment,
applied melting width increases with increasing Evolume . At the laser power of
E μm. .The 3700 W, the melting
3700 W, inthethe experiment,
melting width melting width
is observed increases
with with width
the largest increasing
of 917 At the
E laserispowerdirectlyof
width is observed
3700 W, the melting with the largest
width is width of 917 µm. The E volume is directly proportional E to laser power.
proportional to laser power. Asobserved
the laser with
power the largest width
increases, of 917energy
the thermal μm. The entering theismaterials
directly
Asproportional
the laser power to increases,
laser power.theAsthermal
the energy
laser powerentering the materials
increases, the thermal increases
energy so the melting
entering the width
materials
increases so the melting width is observed with the largest value. In short, the laser beam including
is increases
observed withso the the largestwidth
melting value. isInobserved
short, thewith
laser beam including
value.theIn laser
short,power and beam
cutting speed
the laser power and cutting speed directly affect the
the largest
material. the laser including
directly affect
the laser the material.
power and cutting speed directly affect the material.

Figure 3. Variation of melting width in SS41 according to Evolume .

Figure 3. Variation of melting width in SS41 according to E .
Figure 3. Variation of melting width in SS41 according to E .
Materials 2020, 13, 4596 6 of 15

Materials 2020, 13, x FOR PEER REVIEW 6 of 16

3.3. Analysis of Kerf Width in SUS304 According to Volume Energy
3.3. Analysis of Kerf Width in SUS304 According to Volume Energy
The effect of Evolume on the kerf widths of the top and bottom surface are shown in Figure 4.
The effect of E on the kerf widths of the top and bottom surface are shown in Figure 4.
The kerf width on SUS304 is measured in the same method as SS 41. The kerf widths of the top
The kerf width on SUS304 is measured in the same method as SS 41. The kerf widths of the top and
and bottom surface also increase with increasing Evolume . The kerf widths on the top surface are
bottom surface also increase with increasing E . The kerf widths on the top surface are slightly
slightly larger than those on the bottom surface. At the laser power of 3100 W, the kerf widths of top
larger than those on the bottom surface. At the laser power of 3100 W, the kerf widths of top and
and bottom are observed with the largest width of 796 µm and 375 µm, respectively. As mentioned,
bottom are observed with the largest width of 796 μm and 375 μm, respectively. As mentioned, the
the difference
differencebetween
betweentop topand
andbottom
bottomcan
canbe
becaused
caused by
by various
various factors,
factors, such
such as
as loss of intensity
loss of intensity of
of the
the
beam, defocusing of the laser beam, or loss of gas pressure for the thickness of the materials.
beam, defocusing of the laser beam, or loss of gas pressure for the thickness of the materials. In the In the
case case
of theoftrend on kerf
the trend widths,
on kerf kerfkerf
widths, widths of of
widths thethe
toptopand
andbottom
bottomsurface
surfaceare
areobserved
observed to
to increase
increase
with with
increasing E
increasing E
volume . The specimen is heavily influenced by the laser beam and rapidly
. The specimen is heavily influenced by the laser beam and rapidly heats heats upupto
the vaporization temperature of the material. As the laser power increases, the laser beam
to the vaporization temperature of the material. As the laser power increases, the laser beam enteringentering the
material increases
the material so the kerf
increases widths
so the of the top
kerf widths and
of the topbottom surface
and bottom also increase.
surface also increase.

(a)

(b)

FigureFigure 4. Variation
4. Variation of (a)of (a)top
kerf kerf top and
and (b) kerf
(b) kerf bottom in SUS304 according to EVolume.
bottom in SUS304 according to EVolume .
Materials 2020, 13, 4596 7 of 15
Materials 2020, 13, x FOR PEER REVIEW 7 of 16

3.4.
3.4. Analysis
Analysis of of Heat
Heat Affected
Affected Zone
Zone in in SUS304
SUS304 According
According to to Volume
Volume Energy
Energy
The
The effect
effect of of
thethe EVolumeon
EVolume onHAZ
HAZisisshown
shownininFigure
Figure 5.5.HAZ
HAZisisthethearea
areaininwhich
which the
the microstructure
microstructure
of of a material
a material is is changed
changed byby heat
heat input.If If
input. thethe microstructure
microstructure changes,a microcrack
changes, a microcrack occurs
occurs inin
thethe
processed material, it causes a partial breakdown of the product and deteriorates
processed material, it causes a partial breakdown of the product and deteriorates the quality. Therefore, the quality.
it Therefore,
is important it is
toimportant
reduce thetoHAZ reduce the HAZ
during during
the laser the laser
cutting cutting
so that so that micro-cracks
micro-cracks can be
can be avoided.
Asavoided.
observed Asfrom
observed from the experimental
the experimental results, theresults, thethe
effect of effect of theonEVolume
EVolume on the
the HAZ HAZ
also also increases
increases with
with increasing E
increasing EVolume . The maximum width of HAZ is 800 µm at 3500W and the minimum width of of
Volume . The maximum width of HAZ is 800 μm at 3500W and the minimum width
thethe HAZ
HAZ is is
550550µmμm at 2100
at 2100 W.W. This
This cancan be related
be related to the
to the heatheat
inputinput entering
entering the the material.
material. EVolume
EVolume is is
proportional
proportional to laser
to laser power.
power. As Asthe the
laserlaser
powerpower increases,
increases, the heat
the heat entering
entering materials
materials increase
increase and theand
the spread
spread of heatofdamage
heat damage also increase.
also increase. Therefore,
Therefore, the HAZthe increases
HAZ increases with increasing
with increasing laser power.
laser power.

Figure 5. Variation of the Heat Affected Zone (HAZ) in SUS304 according to EVolume .
Figure 5. variation of the Heat Affected Zone (HAZ) in SUS304 according to EVolume.
The effect of the EVolume on HAZ is shown in Figure 5. HAZ is the area in which the microstructure
of a material is changed
The effect by heat
of the EVolume input.
on HAZ If the in
is shown microstructure
Figure 5. HAZchanges,
is the areaa in
microcrack
which theoccurs in the
microstructure
processed material,
of a material it causes by
is changed a partial breakdown
heat input. If theofmicrostructure
the product andchanges,
deteriorates the quality.occurs
a microcrack Therefore,
in the
it processed
is important to reduce
material, the HAZ
it causes duringbreakdown
a partial the laser cutting
of the so that micro-cracks
product can bethe
and deteriorates avoided.
quality.
AsTherefore,
observed from the experimental
it is important to reduceresults,
the HAZthe effect
duringof the
the Elaser
Volume on theso
cutting HAZ
thatalso increases with
micro-cracks can be
increasing
avoided.EAs . The maximum
observed
Volume width of HAZ
from the experimental was the
results, 800 effect
µm atof3500 WVolume
the E andon thethe
minimum
HAZ also width of
increases
thewith
HAZ was 550 µm
increasing at 2100
EVolume . The W. This canwidth
maximum be related to the
of HAZ was heat
800input
μm atentering
3500 W theandmaterial. EVolume
the minimum is
width
proportional to laser power. As the laser power increases, the heat entering materials
of the HAZ was 550 μm at 2100 W. This can be related to the heat input entering the material. EVolumeincrease and the
spread of heat damage
is proportional to laseralso increase.
power. Therefore,
As the the HAZ
laser power increases
increases, withentering
the heat increasing laser power.
materials increase and
the spread of heat damage also increase. Therefore, the HAZ increases with increasing laser power.
3.5. Multiple Regression
3.5.InMultiple Regression
this section, the regression analysis of laser power and cutting speed in the laser cutting process
is performed. Multiplethe
In this section, regression
regressionanalysis is a of
analysis mathematical
laser powermodel for indicating
and cutting speed inthe suitability
the of
laser cutting
theprocess
relationship between the independent and dependent variable [25]. In the case of
is performed. Multiple regression analysis is a mathematical model for indicating the the regression
model, if the
suitability ofhigh
theorder equationbetween
relationship is used regardless of experiment
the independent data, the variable
and dependent determination
[25]. Incoefficient
the case of
always increases. This problem is called “overfitting”. If the regression
the regression model, if the high order equation is used regardless of experiment model becomes overfitting,
data, the
thedetermination
prediction of coefficient
experimental results
always throughThis
increases. the problem
regressionis model
called becomes meaningless.
“overfitting”. Thus,
If the regression
model becomes overfitting, the prediction of experimental results through the regression model
becomes meaningless. Thus, the regression equation used in this study is the quadratic regression
model and the equation for the regression model is followed by:
Materials 2020, 13, 4596 8 of 15

the regression equation used in this study is the quadratic regression model and the equation for the
regression model is followed by:
n
X n
X n
X
y = β0 + βi Xi + βii X2i + βij Xi Xj , (2)
i=1 i=1 i<j

where β is the regression coefficient and can be calculated using the least-squares method, Xi and Xj
are the independent variables of this regression equation and these are laser power and cutting speed,
respectively, y is the dependent variable and represents measured data. The second-order regression
model has been developed for kerf top width, kerf bottom width, melting width, and HAZ using
data from the experiments. To calculate the regression coefficient β, the coefficients of the quadratic
regression model are calculated. In addition, the determination coefficient (Rsq -value) and the adjusted
determination coefficient (Radj ) are calculated to check whether the data predicted by the regression
model is appropriate. When the determination coefficient is close to 1, the accuracy of regression
model is estimated to be suitable. The regression coefficients are determined by the t-test. The ‘SE
Coef’ represents the standard error of the coefficient, and it is useful for making up a confidence
interval and performing a hypothesis test. The t-test is a statistical method of the standardized value
which is calculated from experimental data. The T-statistic is used to measure the magnitude of
variation for the experimental data. It is calculated from experimental data to compare the null
hypothesis. Each term of coefficients is tested by the null hypothesis according to the p-value. The null
hypothesis is statistical proof to determine that the regression model is statistically significant. It can be
determined by statistical evidence when the experimental data is meaningful. In general, a low p-value
(<0.05) indicates that the predicted model can be meaningful in the experimental data. The regression
coefficient suitability and coefficient of determination are shown in Tables 3 and 4.

Table 3. The regression coefficient of SS41.

Kerftop . Coefficient SE Coefficient T Statistic p-Value

β0 388.6832 80.07202 4.85417 8.75 × 10−6
β1 0.2657 0.033199 8.00299 4.35 × 10−11
β2 −0.00855 0.044628 −0.1916 0.848694
β3 −3 × 10−5 6.2 × 10−6 −4.87501 8.11 × 10−6
β4 −8.5 × 10−7 7.18 × 10−6 −0.1179 0.906538
β5 −7.6 × 10−6 7.02 × 10−6 −1.08053 0.28416
Rsq = 0.90, Rsq (adj) = 0.89
kerfbottom Coefficient SE Coefficient T Statistic p-Value
β0 −5.9335 89.49774223 −0.066297523 0.947357769
β1 0.2503 0.037857046 6.611759502 1.0722 × 10−8
β2 0.0723 0.05112402 1.413235703 0.16266912
β3 −3.289 × 10−5 7.25866 × 10−6 −4.531773519 2.7836 × 10−5
β4 −1.372 × 10−5 8.75522 × 10−6 −1.566708952 0.122356105
β5 6.355 × 10−6 8.60318 × 10−6 0.738711082 0.462915371
Rsq = 0.89, Rsq (adj) = 0.88
Materials 2020, 13, 4596 9 of 15

Table 3. Cont.

Melting Coefficient SE Coefficient T Statistic p-Value

β0 1030.875 112.6616 9.150191 4.76 × 10−13
β1 0.2174 0.046711 4.653414 1.81 × 10−5
β2 −0.4547 0.062792 −7.24157 8.9 × 10−10
β3 −7.995 × 10−6 8.73 × 10−6 −0.91606 0.363242
β4 8.1839 × 10−5 1.01 × 10−5 8.104238 2.91 × 10−11
β5 −2.8654 × 10−5 9.88 × 10−6 −2.8996 0.005187
Rsq = 0.86; Rsq (adj) = 0.85

Table 4. Regression coefficient of SUS304.

Kerftop . Coefficient SE Coefficient T Statistic p-Value

β0 853.0468 251.3251 3.394196 0.001371
β1 0.167979 0.129446 1.297679 0.200474
β2 −0.21867 0.11114 −1.96752 0.054797
β3 −1.1 × 10−6 2.14 × 10−5 −0.05021 0.960161
β4 4.6 × 10−5 1.84 × 10−5 2.498231 0.015886
β5 −5 × 10−5 1.76 × 10−5 −2.82229 0.006871
Rsq = 0.80, Rsq (adj) = 0.78
kerfbotom Coefficient SE Coefficient T Statistic p-Value
β0 −108.267 69.11328 −1.56651 0.123665
β1 0.360518 0.035597 10.12777 1.32 × 10−13
β2 −0.05506 0.030563 −1.8015 0.077778
β3 −5.3 × 10−5 5.9 × 10−6 −8.97845 6.35 × 10−12
β4 8.64 × 10−6 5.06 × 10−6 1.707061 0.094141
β5 −8.1 × 10−6 4.83 × 10−6 −1.67321 0.100659
Rsq = 0.92, Rsq (adj) = 0.91
Heat Affected Zone Coefficient SE Coefficient T Statistic p-Value
β0 2289.716 218.9419 10.4581 4.46 × 10−14
β1 −0.68795 0.112767 −6.10062 1.64 × 10−7
β2 −0.40922 0.09682 −4.22663 0.000103
β3 0.000132 1.87 × 10−5 7.041524 5.72 × 10−9
β4 6.28 × 10−5 1.6 × 10−5 3.913384 0.000281
β5 −1.4 × 10−5 1.53 × 10−5 −0.91761 0.363319
Rsq = 0.85, Rsq (adj) = 0.83

The results based on the regression model for kerf widths of top, bottom surface, and melting
width on SS41 on the laser power and cutting speed are plotted in Figure 6 and mathematical equations
are expressed in Equations (3)–(5), respectively. The regression model of kerftop is shown in Figure 6a
Rsq and Rsq (adj) of the kerf top are 0.90 and 0.89, respectively. When the determination coefficient is
close to 1, the accuracy of the regression model is high. Therefore, the experimental data are suitable
for the regression model. It also shows the most appropriate coefficient of determination among the
regression models. In Figure 6, it is found that the kerftop increases as increasing laser power. On the
Materials 2020, 13, 4596 10 of 15

other hand, the variation of the kerftop is insignificant when the cutting speed increases. However,
the kerftop increases when the laser power and cutting speed increase simultaneously. The regression
model of kerfbottom is shown in Figure 6b. Rsq and Rsq (adj) of kerfbottom are 0.89 and 0.88, respectively.
This regression model is appropriate for the experimental data. It is also found that kerfbottom increase
as the increasing laser power. However, the variation of kerfbottom is not variation when the cutting
speed increases. It is also that the kerftop increases when the laser power and cutting speed increase
simultaneously. This is similar to the experimental result of kerftop . The regression model for melting
width is shown in Figure 6c. The correlation model is suitable for experimental data. Rsq and Rsq (adj)
were 0.86 and 0.85, respectively. This leads to the fact that the data used in the regression model
were well-fitted. In the relationship of the laser parameters, the melting width increases as the
increasing laser power. However, the melting width first decreases when cutting speed increases
up to 3000 mm/min. After the cutting speed of 3000 m/mm, the melting width increases when the
cutting speed increases. In addition, when the laser power and cutting speed increase simultaneously,
the melting width increases.
Materials 2020, 13, x FOR PEER REVIEW 10 of 16
kerftop = 388.6832 + 0.2657X1 − 0.00855X2 − 3 × 10−5 X1 × X1
the regression model. It also shows −7 X appropriate
the10most −6 of determination
coefficient among the
(3)
−8.5 × 2 × X2 − 7.6 × 10 X1 × X2
regression models. In Figure 6, it is found that the kerf increases as increasing laser power. On the
other hand, the variation of the kerf is insignificant when the cutting speed increases.
 However, the
kerf = the−5.9335 + 0.2503X1 − 0.0723X − 3.289 × 10−5 X1The × Xregression
1−
kerf bottomwhen
increases laser
 power and cutting  2
speed increase simultaneously.
 (4)
−5 −6
model of kerf is shown 1.372
in Figure× 106b. RX2 × X2 R− (adj)
and 6.355of×kerf
10 X1 × areX20.89 and 0.88,
respectively. This regression model is appropriate for the experimental  data. Itis also found that
kerf Melting
increase=as the
1030.875
increasing+laser
0.2174X − 0.4547X
power.1 However, the2 variation 10−6 X1 is×not
− 7.995of×kerf X1 −variation
when the cutting speed increases. It is also that
 the kerf increases
 when the
laser power and cutting (5)
8.1839 × 10−5 X2 × X2 − 2.8654 × 10−5 X1 × X2
speed increase simultaneously. This is similar to the experimental result of kerf . The regression
model
kerftop = for melting width is shown
+ 0.167979X in Figure 6c. The correlation
−6 model is suitable
−5 for experimental−5 data. (6)
: 853.0468 1 − 0.21867X2 − 1.1 × 10 X1 × X1 − 4.6 × 10 X2 × X2 − 5 × 10 X1 × X2
R and R (adj) were 0.86 and 0.85, respectively. This leads to the fact that the data used in the
regression
kerftop = : 853.0468model were well-fitted.
+ 0.167979X In the
1 − 0.21867X 1.1 × 10−6 Xof1 ×the
2 −relationship X1laser × 10−5 X2 ×the
− 4.6parameters, X2 melting −5 X × X
− 5 × 10width 1 2 (7)
increases as the increasing laser power. However, the melting width first decreases when cutting speed
increases
Heat Affected Zoneup=to2289.716
3000 mm/min. After1 the
− 0.68795X cutting speed
− 0.40922X of 3000 1m/mm,
2 − 0.000132X × X1 −the × 10−5 Xwidth
6.28melting 2 × X2increases
−5 X × X
− 1.4 × 10when 1 2 (8)
the cutting speed increases. In addition, when the laser power and cutting speed increase
simultaneously, the melting width increases.

Multiple
Figure 6.Figure regression
6. Multiple of of
regression SS41
SS41(a)
(a) kerf top
kerftop , (b)
, (b) kerfkerf
bottombottom
, (c) Melting.
, (c) Melting.

kerf = 388.6832 + 0.2657 X − 0.00855X − 3 × 10 X × X

− 8.5 × 10 X × X − 7.6 × 10 X × X . (3)

kerf = −5.9335 + 0.2503X − 0.0723X − (3.289 × 10 )X × X −

(4)
(1.372 × 10 )X × X − (6.355 × 10 )X × X
Materials 2020, 13, 4596 11 of 15

The regression model for kerf widths and HAZ on SUS304 is shown in Figure 7. The regression
model of kerftop is shown in Figure 7a and mathematical equations are expressed in Equations (6)–(8),
respectively. Rsq and Rsq (adj) are 0.80 and 0.78, respectively. The regression model is relatively suitable
for experimental data. In the relation between laser power and cutting speed, it is found that the kerftop
increases as the decreasing cutting speed but the variation of the kerftop is insignificant when the laser
power increase. When the laser power and cutting speed increase simultaneously the variation of
kerftop is relatively low. The regression model of kerfbottom is shown in Figure 7b. Rsq and Rsq (adj)
of kerfbottom are 0.92 and 0.91, respectively. The experimental data are suitable for the regression
model. It is also the most appropriate decision coefficient among the regression models for SUS304.
In the effects of laser power and cutting speed on kerfbottom , it is also found that kerfbottom increases
as the increasing laser power. However, there is a little variation of the kerfbottom when the cutting
speed increases. When the laser cutting speed increases up to 35,000 mm/min and the laser power
increases up to 3000 W, the kerfbottom increases but, after 3000 W laser power, then it decreases slightly.
The regression model for HAZ is shown in Figure 7c. Rsq and Rsq (adj) are 0.85 and 0.83, respectively.
This regression is in good agreement with the experimental data. In the relationship of the laser
parameters, as the cutting speed increases, HAZ decreases rapidly. In addition, HAZ first decreases
when laser power increases up to 2500 W but after laser power of 2500 W the HAZ increases with
Materials 2020, 13, x FOR PEER REVIEW 12 of 16
increasing the laser power.

Figure 7. Multiple regress of SUS304 (a) kerftop , (b) kerfbottom , (c) Heat Affected Zone.
Figure 7. Multiple regress of SUS304 (a) kerftop, (b) kerfbottom, (c) Heat Affected Zone.
3.6. Analysis of Variance (ANOVA)
3.6. Analysis of Variance
In this section, the (ANOVA)
effect of the laser parameter is investigated through the analysis of variance
(ANOVA).
In thisThe ANOVA
section, statistically
the effect of theanalyzes the effectisof
laser parameter each independent
investigated variable
through on theof
the analysis dependent
variance
(ANOVA). The ANOVA statistically analyzes the effect of each independent variable on the
dependent variable during laser cutting. The advantage of ANOVA can be identified by the
important factors for each independent variable, as well as the interaction effect of each parameter
on laser cutting quality [26]. The variability of the experimental data can be determined by the
percentage of contribution (PCR) of each independent variable. In addition, the results of the
Materials 2020, 13, 4596 12 of 15

variable during laser cutting. The advantage of ANOVA can be identified by the important factors for
each independent variable, as well as the interaction effect of each parameter on laser cutting quality [26].
The variability of the experimental data can be determined by the percentage of contribution (PCR)
of each independent variable. In addition, the results of the ANOVA are represented by the 95%
confidence level (p ≤ 0.05) and it is considered that the independent variable has a statistically significant
effect on the experimental data. Tables 5 and 6 for ANOVA results show Degrees of Freedom (DF),
Sum of Squares (SS), Mean squares (MS), F ratio, and percentage of contribution (PCR). The SS is the
sum of the squared deviations between the mean and the variance of each experimental data. The MS
represents the estimate of the population variance. This is the corresponding sum of squares divided
by degrees of freedom. The F ratio is the distribution ratio obtained through a comparison of variances.
It is used to test whether the variance of each group is different and whether the population mean is
different. The PCR is calculated based on the estimated variance components. The higher PCR indicates
that the variability of the experimental data by independent variables increases. In the results of
ANOVA, the P-value on the effect of each parameter and interaction effects between parameters are less
than 0.05. This indicates that the parameters used have a significant effect on the experimental results.

Table 5. SS41ANOVA table.

Source SS DF MS F Ratio p-Value PCR [%]

Kerftop
Laser Power 5.6 ×106 8 7.0 × 105 4.2 × 103 <0.05 59.28
Cutting Speed 1.2 × 106 7 1.7 × 105 1.0 × 103 <0.05 12.48
Laser power × Cutting speed 2.7 × 106 56 4.7 × 104 2.8 × 102 <0.05 27.99
Error 2.4 × 104 144 1.7 × 102 0.26
Total 9.5 × 106 215
Kerfbottom
Laser Power 4.0 × 106 8 5.0 × 105 1.4 × 103 <0.05 73.06
Cutting Speed 3.1 × 105 7 4.4 × 104 1.2 × 102 <0.05 5.63
Laser power × Cutting speed 1.1 × 106 56 2.0 × 104 5.6 × 10 <0.05 20.37
Error 5.1 × 104 144 3.6 × 102 0.94
Total 5.5 × 106 215
Melting
Laser Power 5.3 ×106 8 6.6 × 105 1.2 × 103 <0.05 59.65
Cutting Speed 1.1 × 106 7 1.5 × 105 2.7 × 102 <0.05 12.08
Laser power × Cutting speed 2.4 × 106 56 4.3 × 104 7.6 × 10 <0.05 27.35
Error 8.2 × 104 144 5.7 × 102 0.92
Total 8.9 × 106 215

The ANOVA results for SS41 are shown in Table 5. ANOVA tables demonstrate the results of
laser power, cutting speed, and laser power × cutting speed for the 95% confidence level (p < 0.05).
At the ANOVA table of kerftop , it shows that the most effective variable is laser power which was
59.28% of the PCR. The other variables affecting kerftop were cutting speed and laser power × cutting
speed, which were 12.48% and 27.99% of PCR, respectively. At the ANOVA table of the kerfbottom ,
the laser power was the most effective variable, which was 73.06% of PCR. The other variables affecting
kerfbottom were cutting speed and laser power × cutting speed, which were 5.63% and 20.37% of PCR,
respectively. As a result of melting width, the PCR of the laser power, cutting speed, and laser power
× cutting speed were found to be 59.65%, 12.08%, and 27.35%, respectively. The ANOVA results for
SUS304 are shown in Table 6. At the ANOVA table of kerftop , it shows that the most effective variable
is laser power × cutting speed which was 78.33% of the PCR. The other variables affecting kerftop were
laser power and cutting speed which were 9.93% and 10.45% of PCR, respectively. As the results of
kerfbottom , it shows that the most effective variable was laser power × cutting speed, which was 40.25%
Materials 2020, 13, 4596 13 of 15

of PCR. The other variables affecting kerfbottom were laser power and cutting speed which were 38.3%
and 20.22% of PCR, respectively. At the ANOVA results of HAZ, the PCR of the laser power, cutting
speed, and laser power × cutting speed were found to be 22.39%, 28.74%, and 40.78%, respectively.
In the case of SS41 analyzed by ANOVA, the most effective variable of kerftop , kerfbottom , and melting
was laser power. On the other hand, at the ANOVA results of SUS304, the most effective variable of
the kerftop was laser power and the most effective variables of kerfbottom and HAZ was laser power ×
cutting speed. The most effective variables of experimental results were different. The reason why the
effective variable is different is the mechanical or chemical properties of metallic materials are different.
In the case of the chemical properties of materials, SUS304 includes the chemical composition of Ni and
Cr. These components improve corrosion resistance and heat resistance. Especially, The Cr component
interacts with the atmosphere of the O and then, the thin film is generated on the SUS304 surface [27].
This thin film can protect from the surface corrosion and heat damage and the effect of laser power
might decrease due to the protecting thin film. Therefore, we assume that the effect of laser power
affecting the material is low. The complex effect of laser power × cutting speed has more influence on
the material than the effect of laser power. The influence of laser parameters on the components such
Ni and Cr needs further study.

Table 6. SUS304 ANOVA table.

Source SS DF MS F Ratio p-Value PCR [%]

Kerftop
Laser Power 9.0 ×104 9 1.0 × 104 1.2 × 102 <0.05 9.93
Cutting Speed 9.5 × 104 6 1.6 × 104 1.9 × 102 <0.05 10.45
Laser power × Cutting speed 7.1 × 105 54 1.3 × 104 1.6 × 102 <0.05 78.33
Error 1.2 × 104 140 8.4 × 10 1.29
Total 9.1 × 105 209
Kerfbottom
Laser Power 1.9 × 105 9 2.1 × 104 3.9 × 102 <0.05 38.03
Cutting Speed 9.9 × 104 6 1.6 × 104 3.1 × 102 <0.05 20.22
Laser power × Cutting speed 2.0 × 105 54 3.6 × 103 6.9 × 10 <0.05 40.25
Error 7.4 × 103 140 5.3 × 10 1.52
Total 4.9 × 105 209
Heat Affected Zone
Laser Power 6.0 ×105 9 6.7 × 104 4.3 × 10 <0.05 22.39
Cutting Speed 7.7 × 105 6 1.3 × 105 8.3 × 10 <0.05 28.74
Laser power × Cutting speed 1.1 × 106 54 2.0 × 104 1.3 × 10 <0.05 40.78
Error 2.2 × 105 140 1.6 × 103 8.09
Total 2.7 × 106 209

4. Conclusions
Nowadays, there are many types of laser systems, such as Nd:YAG laser or CO2 laser. The CO2
laser system has many advantages such as providing good processing quality and high processing
efficiency [28]. To achieve improvement in product quality and productivity, the effects of laser
parameters on the material should be considered as a major issue. In this study, the influences of
the laser parameter, such as laser power and cutting speed on the SS41 and SUS304 are studied.
The experimental results of laser cutting on metallic materials are analyzed through multiple regression
and analysis of variance (ANOVA). The effects of each independent variable to output variables are
analyzed. The conclusions of this experiment are as follows:

1. We confirmed that the experimental results depend on the laser parameters. For the experimental
results on Eline , as Eline increases, the materials are heated until they evaporate rapidly and remove
Materials 2020, 13, 4596 14 of 15

material easily. Furthermore, the laser power increases, the heat entering materials increases and
the spread of heat damage also increases, so the melting and HAZ width also increase.
2. In the case of multiple regression on the SSand SUS it is founded that the experimental results
in kerf widths, melting, and HAZ are affected by laser parameters. The effect of laser power
and cutting speed is analyzed through the multiple regression model. The regression equation
can appropriately predict output variables from independent variables. Besides, the coefficient
of determination (Rsq ) for kerftop , kerfbottom , and melting width for SSare and respectively.
For the SUS the Rsq for kerftop , kerfbottom , and HAZ are and respectively. Each of Rsq is suitable
for experimental data and the regression model makes it possible to predict the effect of laser
parameters on the material.
3. The results of the ANOVA on the SSand SUSanalyze the effect of each independent variable on
the dependent variable during laser cutting. The most effective variable in kerftop , kerfbottom ,
and melting width on SSis laser power. In the case of kerftop on the SUS the most effective
variables are laser power × cutting speed. On the other hand, for the kerfbottom and HAZ,
the interaction effects of the laser power × cutting speed have been found most effective variables.
The most effective variables are determined differently on SS41 and SUS 304. This may be caused
by different chemical properties of metallic materials. Especially, we assumed that the influence
of Ni and Cr components in SUS304 plays a critical role in the laser cutting. Therefore, the effect
of laser cutting parameters on the chemical properties of SUS304 needs further study.

Author Contributions: D.L. and S.S. conceived and designed the experiments; D.L. and S.S. performed the
experiments; D.L., S.S. analyzed the data; D.L., S.S. wrote the paper. All authors have read and agreed to the
published version of the manuscript.
Funding: The research described herein was sponsored by the National Research Foundation of Korea (NRF) grant
funded by the Korean government (MSIP; Ministry of Science, ICT and Future planning) (No. 2019R1A2C1089644).
The opinions expressed in this paper are those of the authors and do not necessarily reflect the views of the sponsors.
Conflicts of Interest: The authors declare no conflict of interest.

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