Analysis and optimization of micro-milling parameters for improving part quality in ultrafine graphite with varying workpiece inclination angles

Micro-milling is recognized as one of the most important manufacturing technologies for producing micro-components/products. Amongst various materials, graphite has an important role in conventional micro-electrical discharge machining electrodes. This paper is focused on the investigation of the effect of micro-milling process parameters on the dimensional accuracy and surface quality of ultrafine grain graphite TTK-4. Depth of cut, spindle speed, stepover distance and feed rate have been considered as process variables of micro ball-end milling in experimental design. Moreover, the influence of the workpiece’s inclination angle was also investigated. Taguchi’s L9 (34) orthogonal array was chosen to design the experiments, whereas grey relational analysis (GRA) was utilized for the multi-objective optimization of the micro ball end milling process with minimum dimensional deviation and minimum arithmetic mean roughness as objective functions. Furthermore, principal component analysis (PCA) was used to extract principal components and identify the corresponding weights for performance characteristics. In order to determine the significance of micro-milling parameters on overall machining performance, analysis of variance (ANOVA) was performed. The result of the study revealed that the proposed approach is adequate to address the multi-objective optimization of micro-milling parameters.