Metal Removal Process Optimisation using Taguchi Method - Simplex Algorithm (TM - SA) with Case Study Applications
In the metal removal process industry, the current practice to optimise cutting parameters adopts a conventional method. It is based on trial and error, in which the machine operator uses experience, coupled with handbook guidelines to determine optimal parametric values of choice. This method is not accurate, is time-consuming and costly. Therefore, there is a need for a method that is scientific, costeffective and precise. Keeping this in mind, a different direction for process optimisation is taken by employing the combined Taguchi method-simplex algorithm (TM-SA) for optimal parametric setting of manufacturing processes. The process parameters were optimised and the efficiency and robustness of the method described in four literature cases. These cases involve high-speed flat-end milling, forming in hydrodynamic deep drawing, cup deep drawing and abrasive assisted drilling. The computations showed that the TM-SA exhibited superior results in one of the cases and equivalent results in others. This implies that the proposed approach could comparably serve as an optimisation framework with significant advantages of reducing experimental costs and allowing variable usages with the requirement of functional derivation. It is also easy to use. The novelty of this article is the application of a distinctly new method in optimisation for cost reduction and variable usages for the metal removal process. Potential applications of the proposed approach by material type is its usage in machining mild steel, grey cast iron, brass and aluminium with HSS and carbon steel, respectively, used as tools.