A novel path planning approach to minimize machining time in laser machining of irregular micro-holes using adaptive discrete grey wolf optimizer

Abstract

As an essential technique in fabricating substrates for flexible printed circuit boards, laser drilling of polyimide films facilitates the production of smaller holes of superior quality, which is crucial for preserving the structural integrity and functional reliability of materials. This advanced technology is increasingly critical in sectors demanding high performance, such as high-speed communications and biomedical devices. However, challenges such as the diverse sizes of micro-holes, their irregular placement, and the inherent limitations of scanning components on speed and operational range make efficient and rapid laser drilling a complex endeavor. In this paper, we develop a processing time evaluation model and present a new adaptive discrete grey wolf optimizer (A-D-GWO). The A-D-GWO utilizes exchange, shift, and 2-opt operations to enhance search efficiency and includes an adaptive parameter mechanism, improving its adaptability to various problem sizes and ensuring faster convergence. Experimental results confirmed the algorithm’s effectiveness, reducing processing times by 38.9%, 53.6%, and 55.5% for files containing 90, 286, and 649 holes, respectively. When compared to traditional algorithms, A-D-GWO showed better stability and accuracy, suggesting its suitability for inclusion in laser processing technologies.