Multi-objective optimization using Taguchi based grey relational analysis for micro-milling of Al 7075 material with ball nose end mill

This study was carried out to understand micro-milling of aluminum material with ball nose end mill and consisted of four stages: experimental work, modelling, mono and multi objective optimization. In the first stage (experimental work), micro-milling experiments were carried out using Taguchi method. The effects of spindle speed, feed per tooth and depth of cut on tool wear, force and surface roughness were investigated. Cutting tools and workpiece surfaces were also inspected via scanning electron microscope. Adhesion and abrasion wear mechanisms during micro-milling of aluminum were observed. Workpiece surfaces had the accumulations of plastically deformed workpiece material due to the high ductility of aluminum. In the second stage (modelling), all data gathered in the experimental works were utilized to formulate first-order models with interaction. These first-order models with interaction could be used to predict responses in micro-milling of aluminum with a minor error. In the third stage (mono-objective optimization), responses were used alone in optimization study as an objective function. To minimize all responses, Taguchi’s signal to noise ratio was used. The effect of control factors on responses was determined by analysis of variance. In the fourth stage (multi objective optimization), responses were optimized simultaneously using grey relational analysis.