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Article

Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters

Department of Mechanical Engineering, Istanbul Technical University, Gumussuyu, Beyoglu, Istanbul 34437, Türkiye
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Author to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2025, 9(8), 258; https://doi.org/10.3390/jmmp9080258 (registering DOI)
Submission received: 6 June 2025 / Revised: 27 July 2025 / Accepted: 31 July 2025 / Published: 1 August 2025

Abstract

In this study, a novel direct laser beam turning (DLBT) approach is proposed for the precision machining of AISI 308L austenitic stainless steel, which eliminates the need for cutting tools and thereby eradicates tool wear and vibration-induced surface irregularities. A nanosecond-pulsed Nd:YAG fiber laser (λ = 1064 nm, spot size = 0.05 mm) was used, and Ø1.6 mm × 20 mm cylindrical rods were processed under ambient conditions without auxiliary cooling. The experimental framework systematically evaluated the influence of scanning speed, pulse frequency, and the number of laser passes on dimensional accuracy and material removal efficiency. The results indicate that a maximum diameter reduction of 0.271 mm was achieved at a scanning speed of 3200 mm/s and 50 kHz, whereas 0.195 mm was attained at 6400 mm/s and 200 kHz. A robust second-order polynomial correlation (R2 = 0.99) was established between diameter reduction and the number of passes, revealing the high predictability of the process. Crucially, when the scanning speed was doubled, the effective fluence was halved, considerably influencing the ablation characteristics. Despite the low fluence, evidence of material evaporation at elevated frequencies due to the incubation effect underscores the complex photothermal dynamics governing the process. This work constitutes the first comprehensive quantification of pass-dependent diameter modulation in DLBT and introduces a transformative, noncontact micromachining strategy for hard-to-machine alloys. The demonstrated precision, repeatability, and thermal control position DLBT as a promising candidate for next-generation manufacturing of high-performance miniaturized components.
Keywords: laser turning; laser frequency; laser scanning speed; laser parameters; austenitic stainless steel; ablation; pulsed laser laser turning; laser frequency; laser scanning speed; laser parameters; austenitic stainless steel; ablation; pulsed laser

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MDPI and ACS Style

Bastekeli, E.O.; Tasdemir, H.A.; Yucel, A.; Bastekeli, B.O. Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters. J. Manuf. Mater. Process. 2025, 9, 258. https://doi.org/10.3390/jmmp9080258

AMA Style

Bastekeli EO, Tasdemir HA, Yucel A, Bastekeli BO. Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters. Journal of Manufacturing and Materials Processing. 2025; 9(8):258. https://doi.org/10.3390/jmmp9080258

Chicago/Turabian Style

Bastekeli, Emin O., Haci A. Tasdemir, Adil Yucel, and Buse Ortac Bastekeli. 2025. "Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters" Journal of Manufacturing and Materials Processing 9, no. 8: 258. https://doi.org/10.3390/jmmp9080258

APA Style

Bastekeli, E. O., Tasdemir, H. A., Yucel, A., & Bastekeli, B. O. (2025). Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters. Journal of Manufacturing and Materials Processing, 9(8), 258. https://doi.org/10.3390/jmmp9080258

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