Experimental Investigation of Cylindrical Grinding Inconel 718 Alloy and Multi-Objective Optimization of Cutting Parameters Using Grey Relational Analysis and Genetic Algorithm

Abstract

Cylindrical grinding is a complex machining process, and optimizing grinding parameters is crucial to achieving the desired surface finish and productivity. Inconel 718 alloys can be challenging during grinding procedures because these materials are poorly machine-able due to their low heat conductivity and extreme hardness. This research was to investigate the influence of process parameters, such as grinding wheel speed, feed rate, and depth of cut, on the response variables of surface roughness, material removal rate, temperature, and tool life. Experiments were performed on a CNC machine on a work piece of Inconel 718, which was commonly used in the aerospace and gas turbine manufacturing industries. A multi-objective optimization problem was solved using a Taguchi-based grey relational analysis and genetic algorithm program in MATLAB R2021. The sample was meshed using the FEM based on heat analysis of temperature by Abaqus software. An analysis of variance was used to assess the validity of the developed model. The findings showed that wheel speed contributed 78.18% and that it was the most significant parameter affecting surface roughness. A minimum surface roughness of 0.080μm was achieved at the lowest value of grinding parameters (0.01mm depth of cut, 0.02mm/rev, and 1200m/min of wheel speed), and a maximum surface roughness of 0.98μm was achieved at the highest value of grinding parameters (0.05mm depth of cut, 0.06mm/rev, and 2100m/min of wheel speed). Feed rate had a significant effect on the material removal rate (36.65%), followed by wheel speed at a percentage contribution of 22.14%. The highest temperature (119.6°C) was observed for higher grinding parameters, and the lowest temperature was obtained for the lowest grinding parameters (85.4°C). A maximum tool life of 1.48 minutes was achieved at the lowest grinding parameters, and a minimum tool life of 1.09 minutes was achieved at the highest grinding parameters. All confirmation tests were carried out using the optimum set point to confirm the standard qualities for cylindrical grinding of the work piece as suggested by the experimental results.Cylindrical Grinding Is A Complex Machining Process, And Optimizing Grinding ParametersIs Crucial To Achieving The Desired Surface Finish And Productivity. Inconel 718 Alloys Can Be Challenging During Grinding Procedures Because These Materials Are Poorly Machine-Able Due To Their Low Heat Conductivity And Extreme Hardness. This Research Was To Investigate The Influence Of Process Parameters, Such As Grinding Wheel Speed, Feed Rate, And Depth Of Cut, On The Response Variables Of Surface Roughness, Material Removal Rate, Temperature, And Tool Life. Experiments Were Performed On A Cnc Machine On A Work Piece Of Inconel 718,Which Was Commonly Used In The Aerospace And Gas Turbine Manufacturing Industries. AMulti-Objective Optimization Problem Was Solved Using A Taguchi-Based Grey Relational nalysis And Genetic Algorithm Program In Matlab R2021. The Sample Was Meshed Using The Fem Based On Heat Analysis Of Temperature By Abaqus Software. An Analysis Of Variance Was Used To Assess The Validity Of The Developed Model. The Findings Showed That Wheel Speed Contributed 78.18% And That It Was The Most Significant Parameter Affecting Surface Roughness. A Minimum Surface Roughness Of 0.080??M Was Achieved At The Lowest Value Of Grinding Parameters (0.01mm Depth Of Cut, 0.02mm/Rev, And 1200m/Min Of Wheel Speed),And A Maximum Surface Roughness Of 0.98??M Was Achieved At The Highest Value Of Grinding Parameters (0.05mm Depth Of Cut, 0.06mm/Rev, And 2100m/Min Of Wheel Speed). Feed Rate Had A Significant Effect On The Material Removal Rate (36.65%), Followed By Wheel Speed AtA Percentage Contribution Of 22.14%. The Highest Temperature (119.6??C) Was Observed For Higher Grinding Parameters, And The Lowest Temperature Was Obtained For The Lowest Grinding Parameters (85.4??C). A Maximum Tool Life Of 1.48 Minutes Was Achieved At The Lowest Grinding Parameters, And A Minimum Tool Life Of 1.09 Minutes Was Achieved At The Highest Grinding Parameters. All Confirmation Tests Were Carried Out Using The Optimum Set Point To Confirm The Standard Qualities For Cylindrical Grinding Of The Work Piece As Suggested By The Experimental Results.