Experimental study on the machining parameters involved in turning aluminum 6061 alloy using a Taguchi-based grey relational analysis

This study investigates the effects of machining process parameters on chip morphology, tool wear, and surface roughness (SR) using a Taguchi-based grey relational analysis with an L9 orthogonal array. The material for the investigation was 6061 aluminum alloy, machined via lathe turning operations. The highest surface roughness (SR) recorded was 0.97 µm at a cutting speed (A) of 251 m/min, a feed rate (B) of 0.15 mm/rev, a depth of cut (C) of 0.2 mm, and a nose radius (D) of 1.2 mm. The maximum material removal rate (MRR) of 335 mm 3 /s was achieved with A 251 m/min, B 0.2 mm/rev, C 0.4 mm, and D 0.4 mm. ANOVA results revealed that cutting speed was the most significant parameter affecting surface roughness, with a percentage contribution of 78.19%. In contrast, the depth of cut was the most critical factor for material removal rate. Scanning electron microscope (SEM) images of the tool tips indicated substantial wear mechanisms, including chipping, abrasion, grooves, notches, and crater wear.