Multi-response optimization of magnetic abrasive finishing process parameters on AISI H13 hot die steel using grey relational analysis

Abstract

This paper presents a new approach for the optimization of machining parameters on magnetic abrasive finishing (MAF) of AISI H13 hot die steel with multiple responses based on the orthogonal array with grey relational analysis. The process has been explored widely for the finishing of plane surfaces on pillar drilling machine. Taguchi orthogonal arrays L27 Designs of experiment method was used for planning of experiments. Total of 27 Experiments were conducted on AISI H13 hot die steel to check the best factor level combination. Five process parameters such as abrasive size, cutting speed, finishing time, machining gap, and magnetic flux density are optimized using multiple responses such as surface roughness (Ra) and metal removal rate (MRR). The Grey Relational Analysis (GRA) was utilized to analyze the results to find the optimum condition and identify the significant parameters affecting the surface roughness and the metal removal rate on H13 hot die steel. Magnetic abrasive finishing machining parameters combination of experiment no. 14 has the highest grey relation grade (GRG) of 0.922. The ideal parameter combination to achieve optimum output are cutting speed of 118.24 m/min, abrasive mesh size of 600, finishing time of 10 min, Machining gap of 1 mm, and Magnetic flux density of 485 gauss. The surface roughness (Ra) value was improved from 0.753 µm to 0.452 µm.