Abstract
In this study, Taguchi with grey relational analysis of experimental data was carried out to determine an optimum combination of process parameters for promoting the surface roughness and the microhardness of dry milling magnesium alloy. According to Taguchi’s signal-to-noise ratio, the optimal process parameters were obtained for desired surface roughness and microhardness, respectively. Moreover, in order to achieve an improved surface quality, the optimum combination of process parameters was determined by grey relational grade. The analysis of variance for grey relational grade showed that feed rate was the most dominant factor influencing surface integrity in milling of magnesium alloy. Finally, the optimum combination of process parameters were validated by confirmation experiments that yield substantially improved multiple quality characteristics. The outcome of the confirmation experiment indicated that the Taguchi with grey relational analysis is an effective method to determine available cutting parameters for a desired surface quality for milling magnesium alloy under dry condition.
Similar content being viewed by others
References
Mordike BL, Ebert T (2001) Magnesium properties applications potential. Mater Sci Eng A 302:37–45
Polmear IJ (1994) Magnesium alloys and applications. Mater Sci Technol 10:1–16
Tönshoff HK, Winkler J (1997) The influence of tool coatings in machining of magnesium. Surf Coat Technol 94:610–616
Byrne GI, Dornfeld DI, Denkena B (2003) Advancing cutting technology. CIRP Ann Manuf Technol 52:483–507
Hou J, Zhao N, Zhu S (2011) Influence of cutting speed on flank temperature during face milling of magnesium alloy. Mater Manuf Process 26:1059–1063. doi:10.1080/10426914.2010.536927
Tomac N, Tonnessen K, Rasch F (1991) Formation of flank build-up in cutting magnesium alloys. CIRP Ann Manuf Technol 40:79–82
Pu Z, Outeiro JC, Batista AC, Dillon OW, Puleo DA, Jawahir IS (2012) Enhanced surface integrity of AZ31B Mg alloy by cryogenic machining towards improved functional performance of machined components. Int J Mach Tools Manuf 56:17–27. doi:10.1016/j.ijmachtools.2011.12.006
Denkena B, Lucas A (2007) Biocompatible magnesium alloys as absorbable implant materials—adjusted surface and subsurface properties by machining processes. CIRP Ann Manuf Technol 56:113–116. doi:10.1016/j.cirp.2007.05.029
Guo YB, Salahshoor M (2010) Process mechanics and surface integrity by high-speed dry milling of biodegradable magnesium–calcium implant alloys. CIRP Ann Manuf Technol 59:151–154. doi:10.1016/j.cirp.2010.03.051
Umbrello D (2013) Investigation of surface integrity in dry machining of Inconel 718. Int J Adv Manuf Technol 69:2183–2190. doi:10.1007/s00170-013-5198-0
Jin D, Liu Z (2011) Effect of cutting speed on surface integrity and chip morphology in high-speed machining of PM nickel-based superalloy FGH95. Int J Adv Manuf Technol 60:893–899. doi:10.1007/s00170-011-3679-6
Sun J, Guo YB (2009) A comprehensive experimental study on surface integrity by end milling Ti–6Al–4V. J Mater Process Technol 209:4036–4042. doi:10.1016/j.jmatprotec.2008.09.022
Hasçalık A, Çaydaş U (2007) Optimization of turning parameters for surface roughness and tool life based on the Taguchi method. Int J Adv Manuf Technol 38:896–903. doi:10.1007/s00170-007-1147-0
Kilickap E (2010) Modeling and optimization of burr height in drilling of Al-7075 using Taguchi method and response surface methodology. Int J Adv Manuf Technol 49:911–923. doi:10.1007/s00170-009-2469-x
Erkan Ö, Demetgül M, Işik B, Tansel İN (2014) Selection of optimal machining conditions for the composite materials by using Taguchi and GONNs. Measurement 48:306–313. doi:10.1016/j.measurement.2013.11.011
Lin CL, Lin JL, Ko TC (2002) Optimisation of the EDM process based on the orthogonal array with fuzzy logic and grey relational analysis method. Int J Adv Manuf Technol 19:271–277. doi:10.1007/s001700200034
Tsao CC (2007) Grey–Taguchi method to optimize the milling parameters of aluminum alloy. Int J Adv Manuf Technol 40:41–48. doi:10.1007/s00170-007-1314-3
Pawade RS, Joshi SS (2011) Multi-objective optimization of surface roughness and cutting forces in high-speed turning of Inconel 718 using Taguchi grey relational analysis (TGRA). Int J Adv Manuf Technol 56:47–62. doi:10.1007/s00170-011-3183-z
Prasanna J, Karunamoorthy L, Raman MV, Prashanth S, Chordia DR (2014) Optimization of process parameters of small hole dry drilling in Ti–6Al–4V using Taguchi and grey relational analysis. Measurement 48:346–354. doi:10.1016/j.measurement.2013.11.020
Mondal S, Paul CP, Kukreja LM, Bandyopadhyay A, Pal PK (2013) Application of Taguchi-based gray relational analysis for evaluating the optimal laser cladding parameters for AISI1040 steel plane surface. Int J Adv Manuf Technol 66:91–96. doi:10.1007/s00170-012-4308-8
Lin J, Lin C (2002) The use of the orthogonal array with grey relational analysis to optimize the electrical discharge machining process with multiple performance characteristics. Int J Mach Tools Manuf 42:237–244. doi:10.1016/S0890-6955(01)00107-9
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Shi, K., Zhang, D. & Ren, J. Optimization of process parameters for surface roughness and microhardness in dry milling of magnesium alloy using Taguchi with grey relational analysis. Int J Adv Manuf Technol 81, 645–651 (2015). https://doi.org/10.1007/s00170-015-7218-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7218-8