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

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%.

Optimizing the five magnetic abrasive finishing factors on surface quality using Taguchi-based grey relational analysis

“…The final stage in calculating the output characteristic using the ideal configuration of operational parameters is the confirming test, which verifies the effectiveness and repeatability of the optimization strategy utilized in this analysis. The expected GRG in the required circumstances can be calculated using the following equations [49].…”

“…Grey relational analysis (GRA)The GRA is a strategy for determining and describing the relationships that exist among a number of different responses. It is comprised of four stages, which are outlined in more detail below[49][50][51][52][53].…”