Analysis and optimization of surface quality while machining high strength aluminium alloy

Abstract

This paper presents a systematic investigation on analysis and optimization of surface quality during turning of high strength Al 7075. In this central composite design based study, the effect of four important machining parameters such as cutting speed, feed rate, depth of cut, and tool nose radius on the surface quality characteristics namely form error i.e. cylindricity error and circularity error, and average surface roughness has been investigated. The material removal rate is also considered as an important response parameter. The analysis of variance study has been conducted to find the statistically significant parameters. The derived empirical relationships predicted the randomly generated test cases with less than 8.51%. Optimization for multiple outputs with conflicting requirements has been done using the principal component analysis and JAYA algorithm that resulted in the absolute deviation of 7.97% with average roughness- 0.64 µm, circularity error- 4.34 µm, cylindricity error- 0.365 µm, and material removal rate-28.63 cm3/min.