Abstract
This study used the Taguchi technique to optimise the parameters for the AISI 304 stainless steel material in an effort to increase tool life, shorten production times, and lessen surface roughness. For the Taguchi process, ANOVA, Machining criteria are used that take tool life, surface roughness, and production time into account. These criteria include feed rate, cutting speed, and depth of cut (ANOVA). The statistical components of the experiment are prepared using Taguchi, GRA, and PCA. Tool life, Surface Roughness, and production time factors are maximised by the trials' findings, which were then used to determine S/N ratios. Then, surface roughness, minimal production time, and overall tool life are predicted using confirmation tests. The results show that cutting speed significantly affects tool life, cutting speed significantly affects production time, and cutting depth significantly affects surface roughness. For maximum tool life, it was discovered that a feed rate of 0.10 mm/rev, a depth of cut of 0.35 mm, and a cutting speed of 500 m/min were the ideal settings. The ideal circumstances for reducing production time include a cutting speed of 500 m/min, a feed rate of 0.20 mm/rev, and a depth of cut of 0.45 mm. The ideal circumstances for producing the lowest surface roughness are a cutting speed of 300 m/min, a feed rate of 0.15 mm/rev, and a depth of cut of 0.45 mm.
Similar content being viewed by others
References
Hasçalık, A., Çayda, U.: Optimization of turning parameters for surface roughness and tool life based on the Taguchi method. Int. J. Adv. Manuf. Technol. 38, 896–903 (2008)
Aouici, H., Yallese, M.A., Fnides, B., Chaoui, K., Mabrouk, T.: Modeling and optimization of hard turning of X38CrMoV5-1 steel with CBN tool: machining parameters effects on flank wear and surface roughness. J. Mech. Sci. Technol. 25(11), 2843–2851 (2011)
Khamel, S., Ouelaa, N., Bouacha, K.: Analysis and prediction of tool wear, surface roughness and cutting forces in hard turning with CBN tool. J. Mech. Sci. Technol. 26(11), 3605–3616 (2012)
Akıncıoğlu, S., Gökkaya, H., Uygur, İ: The effects of cryogenic-treated carbide tools on tool wear and surface roughness of turning of Hastelloy C22 based on Taguchi method. Int. J. Adv. Manuf. Technol. 82, 303–314 (2015)
Kumar, R., Sahoo, A.K., Mishra, P.C., Das, R.K.: Comparative study on machinability improvement in hard turning using coated and uncoated carbide insertspart II modeling, multi-response optimization, tool life, and economic aspects. Adv. Manuf. 6, 155–175 (2018)
Bonfá, M.M., Costa, É.S., Sales, W.F., Amorim, F.L., Maia, L.H.A., Machado, Á.R.: Evaluation of tool life and workpiece surface roughness in turning of AISI D6 hardened steel using PCBN tools and minimum quantity of lubricant (MQL) applied at different directions. Int. J. Adv. Manuf. Technol. 103, 971–984 (2019)
Saini, S., Ahuja, I.S., Sharma, V.S.: Influence of cutting parameters on tool wear and surface roughness in hard turning of AISI H11 tool steel using ceramic tools. Int. J. Precis. Eng. Manuf. 13(8), 1295–1302 (2012)
Tamizharasan, T., Selvaraj, T., Noorul Haq, A.: Analysis of tool wear and surface finish in hard turning. Int. J. Adv. Manuf. Technol. 28, 671–679 (2006)
Viswanathan, R., Ramesh, S., Maniraj, S., Subburam, V.: Measurement and multi-response optimization of turning parameters for magnesium alloy using hybrid combination of Taguchi-GRA-PCA technique. Measurement 159, 107800 (2020)
Papandrea, P.J., Frigieri, E.P., Maia, P.R., Oliveira, L.G., Paiva, A.P.: Surface roughness diagnosis in hard turning using acoustic signals and support vector machine: a PCA-based approach. Appl. Acoust. 159, 107102 (2020)
Umamaheswarrao, P., Ranga Raju, D., Suman, K.N.S., Ravi Sankar, B.: Multi objective optimization of process parameters for hard turning of AISI 52100 steel using Hybrid GRA-PCA. Procedia Comput. Sci. 133, 703–710 (2018)
Krishna Madhavi, S., Sreeramulu, D., Venkatesh, M.: Evaluation of optimum turning process of process parameters using DOE and PCA Taguchi method. Mater. Today Proc. 4, 1937–1946 (2017)
Wonggasem, K., Wagner, T., Trautmann, H., Biermann, D., Weihs, C.: Multi-objective optimization of hard turning of AISI 6150 using PCA-based desirability index for correlated objectives. Proced. CIRP 12, 13–18 (2013)
Gupta, M., Kumar, S.: Investigation of surface roughness and MRR for turning of UD-GFRP using PCA and Taguchi method. Eng. Sci. Technol. Int. J. 2014, 1–12 (2014)
Singarvel, B., Selvaraj, T., Jeyapaul, R.: Multi objective optimization in turning of EN25 steel using taguchi based utility concept coupled with principal component analysis. Proced. Eng. 97, 158–165 (2014)
Kamble, P.D., Waghmare, A.C., Askhedkar, R.D., Sahare, S.B.: Multi objective optimization of turning parameters considering spindle vibration by Hybrid Taguchi principal component analysis (HTPCA). Mater. Today Proc. 4, 2077–2084 (2017)
Lakshmanan, M., Selwin Rajadurai, J., Rajakarunakaran, S.: Machining studies of Al7075 in CNC turning using grey relational analysis. Mater. Today Proc. 39, 1625–1628 (2020)
Soorya Prakash, K., Gopal, P.M., Karthik, S.: Multi-objective optimization using Taguchi based grey relational analysis in turning of rock dust reinforced Aluminum MMC. Measurement 157, 107664 (2020)
Sivaiah, P., Chakradhar, D.: Performance improvement of cryogenic turning process during machining of 17-4 PH stainless steel using multi objective optimization techniques. Measurement 136, 326–336 (2019)
Palanisamy, A., Selvaraj, T.: Optimization of machining parameters for dry turning of Incoloy 800H using Taguchi-based grey relational analysis. Mater. Today Proc. 5, 7708–7715 (2018)
Bhanu Prakash, P., Brahma Raju, K., Venkata Subbaiah, K., Krishnamachary, P.C., ManiKandan, N., Ramya, V.: Application of Taguchi based grey method for multi aspects optimization on CNC turning of AlSi7 Mg. Mater. Today Proc. 5, 14292–14301 (2018)
Anthony Xavior, M., Jeyapandiarajan, P.: Multi-objective optimization during hard turning of AISI D2 steel using grey relational analysis. Mater. Today Proc. 5, 13620–13627 (2018)
Li, N., Chen, Y.-J., Kong, D.-D.: Multi-response optimization of Ti-6Al-4V turning operations using Taguchi-based grey relational analysis coupled with kernel principal component analysis. Adv. Manuf. 7, 142–154 (2019)
Kaushik, N., Singhal, S.: Hybrid combination of Taguchi-GRA-PCA for optimization of wear behavior in AA6063/SiCp matrix composite. Prod. Manuf. Res. 6(1), 171–189 (2018)
Zaman, P.B., Saha, S., Zama, P.B.: Hybrid Taguchi-GRA-PCA approach for multi-response optimisation of turning process parameters under HPC condition. Int. J. Mach. Machinab. Mater. 22(34), 281–308 (2020)
Singh, R.K., Telang, A., Satyabrata, D.A.: Microstructure, mechanical properties and two-body abrasive wear behaviour of hypereutectic Al–Si–SiC composite. Trans. Nonferrous Met. Soc. China 30(1), 65–75 (2020)
Singh, R.K., Telang, A., Das, S.: Microstructure, mechanical, and high-stress abrasive wear behaviour of as-cast and heat-treated Al–Si–SiCp composite. Int. J. Mater. Res. 110(2), 121–129 (2019)
Singh, R.K., Telang, A., Das, S.: The influence of abrasive size and applied load on abrasive wear of Al-Si–SiCp composite. Arab. J. Sci. Eng. 27, 1–2 (2021)
Singh, R.K., Telang, A., Das, S.: Microstructure and mechanical properties of Al–Si alloy in as-cast and heat-treated condition. Am. J. Eng. Res. 5(8), 133–137 (2016)
Kumar, R., Dwivedi, R.K., Ahmed, S.: Stability of retained austenite in carbide free bainite during the austempering temperature and its influence on sliding wear of high silicon steel. SILICON 13(4), 1249–1259 (2021)
Kumar, R., Dwivedi, R.K., Ahmed, S.: Influence of multiphase high silicon steel (retained austenite-RA, ferrite-F, bainite-B and pearlite-P) and carbon content of RA-Cγ on rolling/sliding wear. SILICON 13(10), 3307–3320 (2021)
Kumar, R., Dwivedi, R.K., Ahmed, S.: Wear characteristics and temperature analysis of alloy steel using self-developed wear testing machine. Mater. Today Proc. 18, 2875–2880 (2019)
Kumar, R., Dwivedi, R.K., Ahmed, S.: Tribological behavior of carbide-free bainite in high silicon steel: a critical review. In: Advanced Materials and Manufacturing Processes, pp. 203–211 (2021)
Sharma, S., Dwivedi, R.K., Kumar, R. (2021). Review on the influence of retained austenite on the mechanical properties of carbide-free bainite. In: Advanced Materials and Manufacturing Processes, pp. 191–201. CRC Press
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Rathod, N.J., Chopra, M.K., Chaurasiya, P.K. et al. Design and optimization of process parameters for hard turning of AISI 304 stainless steel using Taguchi-GRA-PCA. Int J Interact Des Manuf 17, 2403–2414 (2023). https://doi.org/10.1007/s12008-022-01021-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12008-022-01021-w