Development and evaluation of a special measurement device for determining optimal machining parameters in machining applications with the taguchi method for CuAl14Fe4Mn2, XCrNiMoTi17 and AlZn5,5MgCu materials

Measurement of cutting forces, vibrations, cutting temperatures, and surface roughness in machining processes is of critical importance to optimize industrial production processes and enhance quality. Therefore, within the scope of this thesis, a low-cost measurement system designed from standard components was developed, calibrated according to EN ISO 376 standards, and classified as a Class 1 measurement device according to the standard. After the design and calibration processes, machining experiments were conducted on prominent materials in the industry, including 7075 series aluminum (AlZn5.5MgCu), Cupral 10 bronze alloy (CuAl14Fe4Mn2), and 316Ti stainless steel (XCrNiMoTi17), to optimize machining parameters (control factors). To determine the optimal levels of control factors, an experimental design was first conducted using the L16(34) orthogonal array of the Taguchi Method. Confidence interval calculations were performed for the results of the experiments and validation experiments according to the Taguchi Method. Multi-criteria optimization using the Taguchi Method-Based Grey Relational Analysis was conducted for the responses obtained from the experiments. As a result of the optimization studies, it was determined that maximizing the specified spindle speeds provided the necessary optimum values for the responses for all materials, while the effect of other control factors on the responses varied depending on the material. Furthermore, all statistical analyses and the consistency of the experiments demonstrated that the measurement system operated reliably.