Influence of Tool Nose Radius and Cutting Performance during Face Milling of Magnesium Alloy for Output Responses by Taguchi based Grey Relation Analysis

Abstract

In order to take advantage of the machining characteristics of magnesium, it is useful to consider recommended tool design and angles. The geometry of the tool can have a large influence on the machining process. Tool geometry can be used to aid with chip flow and clearance, reduce excessive heat generation, reduce tool build up, enable greater feed rates to be employed and improved tool life. This paper presents a new approach for the optimization of machining parameters on face milling of ZE41 with multiple responses based on orthogonal array with grey relational analysis. Machining tests are carried out by inserting 12 mm diameter of insert having 1 flute under dry condition. In this study, machining parameters namely cutting speed, feed and depth of cut and tool node radius are optimized with the considerations of multi responses such as surface roughness, material removal rate, tool wear and thrust force. A grey relational grade is obtained from the grey analysis. Based on the grey relational grade, optimum levels of parameters have been identified and significant contribution of parameters is determined by ANOVA. Confirmation test is conducted to validate the test result. Experimental results have shown that the responses in Machining process can be improved effectively through the new approach.