Experimental Investigations of Process Parameters for Material Removal Rate and Surface Roughness in Magnetic Abrasive Finishing of Hot Die Steel Hd 13 and En 31 Steel

Abstract

quotAchieving high surface quality is critical for various precision industries, including aerospace, automotive, and medical sectors. Traditional finishing methods struggle to meet the stringent requirements of modern materials such as Hot Die Steel (HD13) and EN-31 steel due to their high hardness. This study addresses the challenge of improving surface quality on these materials through Magnetic Abrasive Finishing (MAF) and explores the optimal combination of process parameters to simultaneously maximize material removal rate (MRR) and minimize surface roughness (Ra). newlineThe research employs a systematic approach, utilizing Taguchi orthogonal arrays L27 Designs of Experiment to plan experiments for each material. Multiple regression analysis is then employed to establish empirical relationships between the process parameters (abrasive size, cutting speed, finishing time, machining gap, and magnetic flux density) and the response variables (surface roughness and MRR). Subsequently, the developed models are validated through additional experiments. To address the conflicting objectives of MRR maximization and Ra minimization, multi-objective optimization techniques including Taguchi-based grey relational analysis and Multiobjective Optimization on the Basis of Ratio Analysis (MOORA) are employed. newlineThe study successfully establishes empirical models correlating process parameters with surface roughness and MRR. The validation experiments confirm the accuracy of the developed models. By employing multi-objective optimization techniques, the research identifies optimal parameter combinations for both materials, balancing the conflicting objectives effectively. newlineManufacturers in aerospace, automotive, medical, and other precision engineering sectors can leverage the optimized parameter combinations identified in this study to enhance the surface finish of components made from Hot Die Steel (HD13) and EN-31 steel. quot newline newline