A multi-objective optimization of MQL milling parameters for aluminium alloy using biodegradable oil with fly ash additive

Abstract This study presents a multi-objective optimization of milling parameters for aluminium alloy under minimum quantity lubricant (MQL) conditions, employing biodegradable vegetable oil with and without the addition of fly ash. In this study, milling experiments were conducted based on a Response Surface Methodology (RSM) design of experiments. The effect of cutting speed, feed rate, depth of cut, and types of cutting fluid on the surface roughness (Ra), tool wear (Vb) , cutting force (Fc) and material removal rate (MRR) were investigated. Analysis of variance (ANOVA) was conducted to determine the significance of each parameter on machining performance. The findings indicated that the addition of fly ash to palm oil markedly enhanced surface quality and diminished tool wear. The machining performance improved by 33.8%, 70%, 19.8%, and 12.2% in terms of Ra, Vb, Fc, and MRR, respectively, when fly ash was added to palm oil compared to using palm oil alone. The optimal machining conditions for achieving the best multi-response outcomes were identified as a cutting speed of 3500 rpm, a feed rate of 840 mm min −1 , and a depth of cut of 1.0 mm.