Parametric Study and Optimization of End-Milling Operation of AISI 1522H Steel Using Definitive Screening Design and Multi-Criteria Decision-Making Approach

Abstract

End-milling operation of steel grade material is a challenging task as it is hard-to-cut material. Proper selection of cutting tools, cutting conditions, and cutting process parameters is important to improve productivity, surface quality, and tool life. Therefore, the present study investigated the end-milling operation of AISI 1522H steel grade under minimum-quantity lubrication (MQL) conditions using a novel blend of vegetable oils, namely canola and olive oil. Cutting process parameters considered were spindle speed (s), feed rate (f), depth of cut (d), width of cut (w), and cutting conditions (c), while responses were average surface roughness (Ra), cutting forces (Fc), tool wear (TW), and material removal rate (MRR). Experimental runs were designed based on the definitive screening design (DSD) method. Analysis of variance (ANOVA) results show that feed rate significantly affects all considered responses. Nonlinear prediction models were developed for each response variable, and their validity was also verified. Finally, multi-response optimization was performed using the combinative distance-based assessment (CODAS) method coupled with criteria importance through inter-criteria correlation (CRITIC). The optimized parameters found were: s = 1200 rpm, f = 320 mm/min, d = 0.6 mm, w = 8 mm, and c = 100 mL/h. Further, it was compared with other existing multi-response optimization methods and induced good results.