Investigation and optimization of the laser Polishing parameters for Ti6Al4V

This study investigated the laser polishing of the Ti6Al4V alloy to improve the surface finish and reduce roughness. A comprehensive experimental and simulation approach was employed, utilizing a Brimo MF50 laser system under varying process parameters. The response surface methodology was employed to model the relationship between the reduction in surface roughness and laser power, pulse width, and repetition frequency. Thermal analysis using simulations revealed the optimal combinations of these parameters that would reduce the surface roughness and mitigate adverse effects such as excessive material degradation. The results indicate that the laser power is the main factor determining the surface roughness reduction, with significant contributions from interactions between power, pulse width, and repetition frequency. Experiments show that polishing at a power of 40 W, repetition frequency of 175 kHz, and pulse width of 250 ns results in the highest roughness reduction, consistent with the simulation results. Statistical validation was used to obtain critical insights into the laser–material interaction mechanism and offer practical guidelines for optimizing the laser polishing process in the advanced manufacturing of Ti6Al4V components. In this study, the combination method of simulation, experimentation, and optimization suggested key technological parameters for the Ti6Al4V alloy polishing process using laser, which could be extensively applied in industry.