Integration of RSM and Machine Learning for Accurate Prediction of Surface Roughness in Laser Processing

This study investigates the modeling of surface roughness (Ra) in the laser cutting of EN 10130 steel process by integrating classical statistical and machine learning methods. First, a quadratic model was developed using response surface methodology (RSM) based on a Box–Behnken experimental design with 17 runs, using cutting speed, laser power, and auxiliary gas pressure as input parameters. Although the RSM model achieved an R2 value of 0.8227, there were still some nonlinear deviations between the predicted and experimental values. To improve the prediction accuracy, a regression tree algorithm was applied to model the residuals of the RSM output. The resulting hybrid model, which combines RSM predictions with machine learning-based corrections, yielded a higher R2 of 0.8889 and a lower RMSE compared to the original RSM model. A leave-one-out cross-validation (LOOCV) was performed to evaluate the generalization, which resulted in an RMSE of 0.3241 and an R2 of 0.6039. These findings confirm the effectiveness of the hybrid approach in capturing complex dependencies and improving prediction accuracy, highlighting its potential for advanced process modeling in laser machining.