**ABSTRACT**

This study applies Taguchi’s design of experiment methodology and regression analysis for optimization of process parameters in turning 6061 aluminum alloy using uncoated carbide tool insert under coolant condition (formulated orange seed oil cutting fluid). Experiments for surface roughness and flank wear were conducted using an L16 orthogonal array design and process parameters such as spindle speed, feed rate, and depth of cut. Based on the S/N analysis, the optimal process parameters for surface roughness were 180 rpm spindle speed (level 1), 0.105 mm/rev feed rate (level 1), and 0.5 mm depth of cut (level 1) i.e. A1B1C1 considering smaller-the-better approach. From the ANOVA analysis for surface roughness and flank wear for aluminum alloy, it shows that depth of cut is the most significant factor, followed by spindle speed. The mathematical models have been developed and adequate because all the multiple regression analysis indicates the fitness of experimental measurements which is within 0.8 and 1. Grey relational analysis combined with Taguchi method has been proposed. It is observed that there is a good agreement between the predicted values (0.884) and experimental values (0.929) and there is improvement of grey relational grade for optimal parameter combination (A2B1C1) is found to be 4.84% through the proposed methodology. From the study, it is concluded that the machining performance is significantly improved using formulated orange seed cutting fluid.

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