Optimization of surface roughness using rotary ultrasonic machine of polyvinyl butyral glass with Taguchi and grey relational analysis

Abstract

Purpose The purpose of this study to identify and optimize the machining of polyvinyl butyral (PVB) material for industrial uses. The research is based on input machining parameters of rotary ultrasonic machining for better understand the output response surface roughness (SR) property of polyvinyl butyral (PVB) by using the Taguchi approach. The grey relational grade analysis (GRG) is also implemented to resolve the complex interrelationship of SR data for optimization and predicting and validate the results. Design/methodology/approach In experimental work, the input parameters, namely, concentration, abrasives, power rate, grit size, tool material and hydrofluoric (HF) acid has been selected. The experiment’s design was created using MINITAB Software; the L27 orthogonal array was selected for the experimentation. SR was examined with the GRG technique for process optimization. On the other hand, for single parameter optimization analysis of variance (ANOVA) has been used. Findings ANOVA optimization technique gives the best result on concentration (40%) of abrasive (Al2O3+SiC+B4C), power rate (40%), grit size (600), HF acid (1.5%) and tool material (D2 alloy) are the optimal parameters to provide the slightest degree of SR. GRG optimization of multi-response parameter setting: 40% concentration, SiC+B4C mixed abrasive slurry, 40% of power rating, 280 grit size, 0.5% HF acid and high-speed tool steel tool material gives better results. The SR of PVB glass material improved by 20% after grey relational analysis. Research limitations/implications There are several practical applications in a variety of material processing sectors, including metallurgy, machinery, electronics and transportation. These real-world applications have produced substantial and discernible economic benefits. Practical implications The analytical and optimization results will be used in the various material processing sectors, including metallurgy, machinery, electronics and transportation. Originality/value The ANOVA and grey theory approaches offer the reader a primary picture of the machining research and process parameter optimization. Combined abrasive slurry of Al2O3+SiC+B4C with a high power-rating exhibits lower SR. Similarly, grit size is vital; larger grits produce better SR. Ra – 0. 611 m is the lowest SR value at the hole found in trial 25 after the experimentation.