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<p>This study aims to optimise the dry milling process of AZ63 magnesium alloy by analysing the effects of key machining parameters on material removal rate (MRR), cutting forces, and surface roughness. AZ63 is valued for its high strength, low density, and excellent corrosion resistance. The Taguchi approach is used in experimental design to systematically analyze the effects of spindle speed, feed rate, depth of cut, and sample conditions, such as cast and heat-treated (T4 and T6 {CA and DA}) AZ63 alloy, on milling performance. The surface roughness parameters considered include Ra (arithmetic mean roughness), Rz (mean peak-to-valley height), Sa (areal arithmetic mean height), and Sz (maximum height of the surface), along with the material removal rate (MRR), and cutting force were considered the critical output responses for the study. The experimental results show that the surface roughness (Ra) ranged from 0.082 to 0.220&#xa0;μm, the material removal rate (MRR) from 0.196 to 3.267&#xa0;g/min, and the cutting force from 6.868 to 110.563&#xa0;N. This study develops a simple and effective Taguchi–TOPSIS approach to optimize process parameters and improve response variables. The results indicate that the conventionally age-hardened (CA) sample, combined with a feed rate (f) of 250&#xa0;mm/min, a depth of cut (d) of 1.25&#xa0;mm, and a spindle speed (S) of 2500&#xa0;rpm, is the best milling setting for AZ63 magnesium alloy. The ANOVA results reveal that the sample condition (28.09%) is the most influential parameter on the closeness coefficient, followed by the feed rate (17.96%).</p>

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Parameteric optimization of dry milling process on stir-cast and heat-treated AZ63 magnesium alloy using TOPSIS method

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Tamil Selvan Murugan,
  • Sudharsan Saravanan,
  • Raja Annamalai Arunjunai Rajan

摘要

This study aims to optimise the dry milling process of AZ63 magnesium alloy by analysing the effects of key machining parameters on material removal rate (MRR), cutting forces, and surface roughness. AZ63 is valued for its high strength, low density, and excellent corrosion resistance. The Taguchi approach is used in experimental design to systematically analyze the effects of spindle speed, feed rate, depth of cut, and sample conditions, such as cast and heat-treated (T4 and T6 {CA and DA}) AZ63 alloy, on milling performance. The surface roughness parameters considered include Ra (arithmetic mean roughness), Rz (mean peak-to-valley height), Sa (areal arithmetic mean height), and Sz (maximum height of the surface), along with the material removal rate (MRR), and cutting force were considered the critical output responses for the study. The experimental results show that the surface roughness (Ra) ranged from 0.082 to 0.220 μm, the material removal rate (MRR) from 0.196 to 3.267 g/min, and the cutting force from 6.868 to 110.563 N. This study develops a simple and effective Taguchi–TOPSIS approach to optimize process parameters and improve response variables. The results indicate that the conventionally age-hardened (CA) sample, combined with a feed rate (f) of 250 mm/min, a depth of cut (d) of 1.25 mm, and a spindle speed (S) of 2500 rpm, is the best milling setting for AZ63 magnesium alloy. The ANOVA results reveal that the sample condition (28.09%) is the most influential parameter on the closeness coefficient, followed by the feed rate (17.96%).