Abstract:
In the machining process large amounts of heat are generated, and in order to remove them, it
is necessary to utilize cutting fluids or adequate cooling agents, both of which are significant
sources of waste production and detrimental to the environment. Due to these issues with cutting
fluids, researchers were forced to develop novel methods, including dry machining, MQL,
compressed air-assisted machining, and cryogenic machining. In this study, the key turning
factors, such as cutting speed, feed rate, and tool overhang, were examined using the design of
experiments to determine how they affected material removal rate and arithmetic average
roughness (Ra) when turning AISI 1018 steel. Experiments were performed under dry cutting
(DC) and compressed-air-assisted machining. Tests were designed according to Taguchi’s L9
orthogonal array. An ANOVA analysis was performed to determine the importance of
machining parameters on the Ra and MRR using Minitab 18 software. Taguchi and an artificial
neural network approach were used for output modeling. Finally, multi-objective optimization
of the machining parameters was performed using Taguchi integrated with a genetic algorithm
to minimize the surface roughness and maximize the material removal rate simultaneously using
Mat lab R2019a. The findings showed that the material removal rate and roughness are
significantly impacted by the cutting speed, followed by feed and tool overhang for dry and
compressed air-assisted machining, respectively. Additionally, Taguchi models and artificial
neural networks show strong correlations with experimental data. But artificial neural network
models show more accuracy. The optimum machining parameters for multi-objective
optimization during dry machining is Vc= 95.935 m/min, F = 0.104 mm/rev, and TOH = 40.024
mm, and the optimum result is MRR = 33.592 mm3
/sec and Ra = 1.443µm. Also, the optimum
machining parameters during air assisted machining is Vc = 93.555 m/min, F = 0.1 mm/rev,
and TOH = 41.701 mm, and the optimum result is MRR = 32.623 mm3
/sec, Ra = 0.468 µm.
