Experimental and numerical investigations on plain turning of AA 8011 alloy using grey relational analysis

Abstract

The current study investigates the effect of major process parameters on the plain turning process, such as Speed (S), feed (F), and depth of cut (DOC). The work piece material chosen is Aluminium (AA8011), and the output responses considered are Cutting force (CF), Material removal rate (MRR), surface roughness (SR), and amplitudes (Amp) of vibrations. In this present work, forces and vibrations of the tool are determined using a dynamometer and vibrometer. The nature of amplitude is identified with respect to speed and depth of cut. Three levels of variation are applied to the input process parameters (S, F, DOC). Experiments are carried out on an All-geared lathe machine following the orthogonal array (L9). A multi-optimization is also performed using Grey relation analysis, with equal weightage given to cutting force, Material removal rate (MRR), surface roughness (SR), and amplitudes (Amp). The significant input process parameters are Speed (higher values: 1200), feed (moderate: 0.003), and Depth of cut (higher values: 0.6), which are the optimal levels for minimizing surface roughness and amplitude while maximizing Material removal rate.