Manufacturing industries are being continuously challenged to achieve higher productivity

and high-quality products in order to remain competitive. The surface roughness, roundness,
machining force, cutting power and material removal rate are some of the important quality
characteristics in turning operation. In order to achieve a better roundness, better surface
finish, minimum machining force, minimum cutting power and maximum material removal
rate, a combination of the turning parameters must be selected within the operating ranges. In
this work, the Grey relational analysis is applied in turning of AA6063 T6 aluminium alloy.
The Grey relational analysis is used for the multi-response optimization of cutting parameters
like cutting speed, feed rate and depth of cut with the simultaneous consideration of multi-
responses such as surface roughness (Ra), roundness (Ø) and material removal rate (MRR)
and the effectiveness of the technique was studied. The multi-response optimization
techniques namely Taguchi-Fuzzy optimization technique and Grey-Fuzzy optimization
technique are applied to the turning of AA 6351 T6 material to optimize the cutting
parameters like cutting speed, feed rate and depth of cut by considering the multi-responses
such as surface roughness (Ra), material removal rate (MRR), machining force (Fm) and
cutting power (Pc) simultaneously and the effectiveness of these techniques were compared.
By comparing the results of the two multi-response optimization techniques namely Taguchi-
Fuzzy optimization technique and Grey-Fuzzy optimization technique, it is concluded that
the Taguchi-Fuzzy optimization technique has outperformed the Grey-Fuzzy optimization
technique, in giving the precise optimal combination of machining parameters. The single-
response optimization techniques like Response surface methodology and Genetic algorithm
technique are applied to the turning of AA 6351 T6 material to optimize the cutting
parameters like cutting speed, feed rate and depth of cut by considering the responses such as
surface roughness (Ra), material removal rate (MRR), machining force (Fm) and cutting
power (Pc) individually and the effectiveness of these techniques were compared.
Experimental results have been compared with theoretical results and they are found to be in
good agreement. By comparing the results of the two single response optimization
techniques namely Response surface methodology and Genetic algorithm technique, it can be
concluded that the Genetic algorithm technique has outperformed Response surface
methodology technique, in giving the precise optimal combination of machining parameters.
The correlation between chip formation and workpiece surface finish has been studied
through the comparison between chip form and roughness parameter for different cutting
conditions. The influence of the cutting speed, feed rate and depth of cut in determining the
shape of the chip during turning of AA6351 T6 was also studied. SEM images have been
obtained from the surfaces of the workpiece materials machined at different cutting
conditions. SEM images have also been obtained from the top surface of the cutting inserts
used for different cutting conditions. From the SEM analysis, it was concluded that the
optimal combination of machining parameters to give better quality characteristics are lower
cutting speed, lower feed rate and lower depth of cut.