Optimization of Machining Parameters of Standard and Edge Chamfered Polycrystalline Diamond Cutting Tools using Taguchi, Entropy – GRA Approaches

Abstract

Machining the Al 7075 alloy using polycrystalline diamond (PCD) tools with a high-quality surface finish is difficult. To solve this challenge, numerous researchers across the globe are experimenting with different kinds of cutting tools and optimising machining settings to get better cutting forces and surface roughness. The authors utilised a conventional edge chamfered (80 µm) PCD cutting tool to machine Al 7075 alloy. The primary goal of this study is to use Taguchi-Entropy-Grey Relational Analysis to discover the best machining parameters, such as cutting speed, feed rate, and depth of cut. Initially, a L9 orthogonal array was created using the Taguchi technique to perform the trials. The ideal responses were determined using a grey relational analysis (GRA), which included cutting force, thrust force, shear force, ploughing force, and surface roughness. Furthermore, the GRA's weight values are assessed using an entropy approach. Finally, the GRA with entropy identifies the best combination of machining parameters for Al 7075 alloy utilising the conventional and edge chamfered PCD cutting tools. The weighted GRA with Taguchi shows that the ideal combination of machining parameters for normal PCD cutting tools is v=314m/min, f=0.10 mm/rev, and d=0.1 mm, while for chamfered PCD cutting tools is v=785m/min, f=0.10 mm/rev, and d=0.2 mm. Finally, the ideal findings were compared to Taguchi's anticipated and experimental values for weighted GRG. The results demonstrate that there is no improvement when using the regular PCD cutting tool and a 20.34% improvement when using the chamfered PCD cutting tool to machine Al 7075 alloy. It concludes that the chamfered PCD cutting tool gets superior results than the conventional PCD cutting tool while milling the Al 7075 alloy.