Optimization and Performance Analysis of Uncoated and Coated Carbide Inserts during Hard Turning AISI D2 Steel Using Hybrid GRA-PCA Technique

Abstract

In this analysis turning parameter optimization is performed during machining AISI D2 steel with uncoated and coated cemented carbide cutting inserts using a hybrid multi-objective optimization technique Grey relational analysis (GRA) and Principal Component analysis (PCA). A L16 Taguchi’s orthogonal array design is selected for basic experimental design considering four levels for the chosen four parameters. Output performance measures viz., tool wear, roughness on finished surface and material removed are evaluated by determining grey relational coefficient, and deriving multi response performance index (MRPI) using principal components. Contribution of coated cutting insert is 72.87% towards the MRPI and 17.15% contribution by feed rate, as determined from Analysis of Variance (ANOVA). Confirmation experiment performed with optimum conditions provides lower tool wear, higher material removal and good surface finish. The MRPI of the confirmation experiment is also confirmed by calculating the confidence interval.