Multi-response optimization of process parameters using Desirability Function Analysis during machining of EN31 steel under different machining environments

Abstract

Abstract In recent years, industries are opting for machining at high cutting speed to gain higher productivity without compromising the quality of the product. High-speed machining results in higher cutting zone temperature which adversely affects the surface qualities, dimensional accuracy of the components and also the tool performance. Thus, it becomes essential to determine the optimal value of machining parameters and cutting conditions that can provide superior results in terms of tool performance and surface qualities. In this study, Face milling operations were performed on EN-31 alloy steel as per Taguchi orthogonal L18 array using tungsten carbide inserts in different cooling environments by varying the lubricant flow rates. Desirability Function Analysis (DFA) was used for concurrent optimization of Tool flank wear and Surface Roughness. The optimal parameter combination for multi-responses is obtained and results show an improvement in composite desirability (CD) at optimum parameter setting. Further, Regression analysis was utilized to develop the mathematical model for the determination of the relationship between process variables and output responses.