Optimization of Process Parameters for End Milling Operation on EN-31 Using Taguchi-Grey Relation

Abstract

A material with exceptional levels of abrasion resistance, compressive strength, and hardness is known as bearing steel, also known as EN-31 high-grade carbon alloy steel. It has several uses, including the bulk manufacturing of roller bearings, taps, gauges, ejector pins, swaging dies, etc. The lowest surface roughness (Ra) and highest material removal rate (MRR) are sought for this alloy steel in order for it to be used successfully in a range of applications. In the experiment, a L9 Taguchi orthogonal array design was used to CNC end mill EN-31 steel using a bullnose end mill carbide tool with inserts. This study presents a way for enhancing process factors such as cutting speed, depth of cut, feed rate, and tool corner radius that result in desirable output responses. Taguchi and Taguchi-Grey analyses are used to show the best input values that reduce surface roughness and increase MRR. The lowest level of surface roughness could be attained using the operating parameters of 3000 rpm cutting speed, 500 mm/min feed rate, 0.25 mm depth of cut, and 1.00 mm tool corner radius, while the highest level of material removal rate could be attained using 3000 rpm cutting speed, 2500 mm/min feed rate, 0.25 mm depth of cut, and 1.00 mm tool corner radius.