Laser-assisted turning of yttria-stabilized zirconia: multi-response

This study investigates multi-objective optimization of surface roughness (Ra) and maximum flank wear (VBmax) in laser-assisted turning (LAT) of yttria-stabilized zirconia (YSZ) ceramics. Straight cylindrical turning experiments were conducted using a Plackett–Burman design for factor screening, steepest ascent for center-point determination, and a 29-run Box–Behnken design for response surface modeling. Gray relational analysis (GRA) was employed for multi-objective optimization, followed by five validation experiments. The quadratic regression models achieved relative prediction errors below 2.5%. Optimal conditions were identified as 100 W laser power, 261.7 mm/s cutting speed, 0.2 mm depth of cut, and 5 mm/min feed rate, yielding Ra of 0.592 μm and VBmax of 120.01 μm. The optimized process promotes brittle–ductile transition while reducing thermal damage and adhesive wear, providing a systematic approach to precision machining of hard and brittle ceramics.