Surface quality improvement of AZ31 Mg alloy by a combination of modified Taguchi method and simple multi objective optimization procedure

Abstract

The motive of this study is to evaluate the machinability properties of AZ31 Mg alloy in the face milling operations. Depth of cut, rate of feed and speed of cut are three input variables in the face milling process, while surface roughness (Ra) and tool nose radius deviation (dR) are performance characteristics. For three input variables each with three levels, to decrease the number of experiments, an L₉ orthogonal array (OA) of Taguchi was employed which enables an efficient approach for conducting a full-factorial design of experiments. Selection of optimal parameters for the face milling process to achieve the required surface quality is accomplished through the utilization of a modified Taguchi approach and a novel multi objective optimization procedure. The work establishes empirical relationships that correlate the performance characteristics (i.e. Ra and dR) with three input variables. Corrections to the empirical relations were specified to obtain the expected range of Ra and dR. Ra and dR estimates were validated with existing test data.

Keywords:

• AZ31 Mg alloy
• depth of cut
• face milling
• rate of feed
• speed of cut
• surface roughness
• Taguchi method
• tool nose radius

Reviewing Editor:

• Professor Swadesh Kumar Singh, Gokaraju Rangaraju Institute of Engineering and Technology, India

Subjects:

• Mechanical Engineering
• Manufacturing Engineering
• Mathematics & Statistics for Engineers

Author contributions

Conceptualization: M.T.A., N.R.B. and S.K.; Methodology: N.R.B. and M.T.A.; Data Collection: P.P.T.P. and S.K.; Analysis and Results interpretation: N.R.B. and M.T.A.; Validation of Results: T.B. and S.K.; Preparation of Draft Manuscript: M.T.A., N.R.B., P.P.T.P.; Manuscript Review and Editing: K.I.U. and R.D.; visualization: T.B., R.D., M.T.A. and N.R.B.; supervision: T.B. and K.I.U. The final version of the manuscript was reviewed and approved by all authors.

Disclosure statement

The authors disclosed no potential conflicts of interest.

Data availability statement

The authors confirm that the data supporting the findings of this study are available within the article.

Additional information

Funding

No funding was received for this work.

Notes on contributors

Muni Tanuja Anantha

Muni Tanuja Anantha M.Tech (Ph.D), Assistant Professor, Anurag University, Hyderabad, Sheet Metal Processing.

Sireesha Koneru

Sireesha Koneru M.Tech (Ph.D), Assistant Professor, KLEF deemed to be university, Guntur, Design.

Parameshwaran Pillai Thiruvambalam Pillai

Parameshwaran Pillai Thiruvambalam pillai PhD (Manufacturing Engineering), University College of Engineering, BIT Campus, Tiruchirappalli, Fracture Mechanics, Composite Materials.

Nageswara Rao Boggarapu

Nageswara Rao Boggarapu Ph.D, Professor, KLEF deemed to be university, Theoretical and Applied Mechanics, Non-Destructive Testing.

Tanya Buddi

Tanya Buddi Ph.D, Associate Professor, GRIET, Hyderabad, Wood based Bio-Composites, Nano Composites, Sheet Metal Forming.

Kseniia Iurevna Usanova

Kseniia Iurevna Usanova M.Tech, Peter the Great St.Petersburg Polytechnic University: Sankt-Peterburg, Renewable Energy Resources.

Rajesh Deorari

Rajesh Deorari Ph.D, Uttaranchal University, Dehradun, Face milling, Powder Metallurgy.