Optimization of Cutting Parameters for Milling Process of (4032) Al-Alloy using Taguchi-Based Grey Relational Analysis

  • Sami Abbas Hammood Department of Production Engineering and Metallurgy/ University of Technology/ Baghdad/ Iraq

Abstract

The objective of this work is to study the influence of end milling cutting process parameters, tool material and geometry on multi-response outputs for 4032 Al-alloy. This can be done by proposing an approach that combines Taguchi method with grey relational analysis. Three cutting parameters have been selected (spindle speed, feed rate and cut depth) with three levels for each parameter. Three tools with different materials and geometry have been also used to design the experimental tests and runs based on matrix L9. The end milling process with several output characteristics is solved using a grey relational analysis. The results of analysis of variance (ANOVA) showed that the major influencing parameters on multi-objective response were spindle speed and cutting tool with contribution percentage (52.75%, 24%), respectively. In addition, the optimum combination of end milling process parameters was then validated by performing confirmation tests to determine the improvement in multi-response outputs. The confirmation tests obtained a minimum (surface roughness and micro-hardness) and maximum metal removal rate with grey relational grade of 0.784 and improvement percentage of 2.3%.

Downloads

Download data is not yet available.

References

S. Ajith Arul Daniel, R. Pugazhenthi, R. Kumar, S. Vijayananth, "Multi objective prediction and optimization of control parameters in the milling of aluminum hybrid metal matrix composites using ANN and Taguchi-grey relational analysis," Defence Technology, vol. 15, no.4, pp. 545-556, 2019.

J Santhakumar, U Mohammad Iqbal, M Prakash. "Optimization of one direction tool path orientation for pocket milling of Ti-6Al-4V using taguchi based grey relational analysis," IOP Conference Series: Materials Science and Engineering, vol. 402, no.1, pp.1-15, 2018.

Luis Wilfredo Hernández-González, Roberto Pérez-Rodríguez, Ana María Quesada-Estrada & Luminita Dumitrescu. "Effects of cutting parameters on surface roughness and hardness in milling of AISI 304 steel," dyna rev.fac.nac.minas, Medellín , vol. 85, no. 205, pp. 57-63, June. 2018.

A.Ranga Subbaiah, N.M.Sivaram and P.Senthil, "Effect of Milling Parameters on Surface Quality of AA6063-T6 Aluminium Alloy During High Speed CNC Face Milling," International Journal of Chem Tech Research, vol.10, no.3, pp.410-421, 2017.

Shunyao Du, Minghe Chen, Lansheng Xie, Zhishou Zhu, Xinnan Wang. "Optimization of process parameters in the high-speed milling of titanium alloy TB17 for surface integrity by the Taguchi-Grey relational analysis method," Advances in Mechanical Engineering, vol. 8, no.10, pp. 1-12,2016.

Sk. Mahaboob johny, Ch. Ramya sri sai, v. Ramakrishna rao, B. Govind singh," Multi-Response Optimization of Aluminum alloy using GRA & PCA by employing Taguchi Method," International Research Journal Engineering Technology, vol. 03, no. 01, Jan.2016.

A.Venkata Vishnu, K. B. G. Tilak, G.Guruvaiah Naidu, Dr. G.Janardhana Raju, "Optimization of Different Process Parameters of Aluminium Alloy 6351 in CNC Milling Using Taguchi Method," International Journal of Engineering Research and General Science, vol. 3, no. 2, Part 2, March-April. 2015.

Lakshmipathi Tammineni, Hari Prasada Reddy Yedula, "Investigation of Influence of Milling Parameters on Surface Roughness and Flatness," International Journal of Advances in Engineering & Technology, vol. 6, no. 6, pp. 2416-2426, Jan. 2014.

Krolczyk, G., Nieslony, P. and Legutko, S. "Microhardness and surface integrity in turning process of duplex stainless steel (DSS) for different cutting conditions," Journal of Materials Engineering and Performance, vol. 23, no. 3, pp.859–866, 2014.

Jihong Yan, Lin Li, "Multi-objective optimization of milling parameters - the trade-offs between energy, production rate and cutting quality," Journal of Cleaner Production, vol. 52, pp.462-471, 2013.

Lohithaksha M. Maiyar, R. Ramanujam, K. Venkatesan, J. Jerald, "Optimization of Machining Parameters for end Milling of Inconel 718 Super Alloy Using Taguchi based Grey Relational Analysis," Procedia Engineering, vol. 64, pp.1276-1282, 2013.

Liu, Y., Zhang, L.T. and Xu, Z.H., "Experimental investigation on high-speed milling of aluminum alloys," In Advanced Materials Research, Trans Tech Publications, vol. 418, pp.1141-1147, 2012.

Surasit Rawangwong, Jaknarin Chatthong, R. Burapa and W. Boonchouytan, "An investigation of optimum cutting conditions in face milling aluminum 7075-T6 using design of experiment," In 4th International Conference on Applied Operational Research, Proceedings, vol. 4, pp. 125-135. 2012.

Thakur, D.G., Ramamoorthy, B. and Vijayaraghavan, L., "Effect of cutting parameters on the degree of work hardening and tool life during high-speed machining of Inconel 718," The International Journal of Advanced Manufacturing Technology, vol. 59, no. 5, pp.483-489, 2012.

Pankul Goel, Zahid A. Khan, Arshad Noor Siddiquee, Shahrul Kamaruddin, Rajeev Kumar Gupta., "Influence of slab milling process parameters on surface integrity of HSLA: a multi-performance characteristics optimization," The International Journal of Advanced Manufacturing Technology, vol. 61, pp.859–871, 2012.

C. C. Tsao. "Grey–Taguchi method to optimize the milling parameters of aluminum alloy," The International Journal of Advanced Manufacturing Technology, vol. 40, pp.41-48, 2009.

Aqeel Sabree Bedan, Halah Ali Habeeb, "An investigation study of tool geometry in single point incremental forming (SPIF) and their effect on residual stresses Using ANOVA Model," Al-Khwarizmi Engineering Journal, vol. 14, no.2, pp. 1- 13, June. 2018.

Aseel Jameel Haleel,"Optimization Drilling Parameters of Aluminum Alloy Based on Taguchi Method," Al-Khwarizmi Engineering Journal, vol. 14, no.2, pp. 14 - 21, June. 2018.

Published
2021-09-13
How to Cite
Hammood, S. (2021). Optimization of Cutting Parameters for Milling Process of (4032) Al-Alloy using Taguchi-Based Grey Relational Analysis. Al-Khwarizmi Engineering Journal, 17(3), 1-12. https://doi.org/10.22153/kej.2021.06.001