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Laser drilling is a popular method as it eliminates the problem of chatter and vibration due to the absence of physical contact between the tool and workpiece. Tool breakage, a common phenomenon that occurs due to bending of the tool in making of slender holes using conventional drilling, can also be avoided. However, quality of the hole measured in terms of circularity, taper and spatter area is the major concern during laser drilling. The present investigation attempts to find out the optimum parametric setting during drilling of Ti6Al4V using CO 2 laser in order to achieve quality holes. Experiments have been conducted to assess the influence of machining parameters, viz. flushing pressure, laser power and pulse frequency, on the performance characteristics such as taper of kerf, heat-affected zone (HAZ) and spatter area. Taguchi's L 9 orthogonal array has been used to design the experimental layout as it reduces the experimental cost and time. Analysis of variance has been performed to assess the effect of machining parameter on the performance characteristics. It has been observed that laser power has significant influence on taper of kerf, HAZ and spatter area. Based on desirability approach, the study suggests that all the performance characteristics can be simultaneously optimized at flushing pressure of 40 Pa, laser power of 2250 W and pulse frequency of 1600 Hz. The study also presents a numerical model to simulate the laser drilling process. Since comparison of experimental and numerical model shows a relative error within 10%, adequacy of the numerical model for assessment of quality characteristics of laser drilled holes is justified.

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