Volume 02, No. 4, April 2016 Page26 Multi-Objective Optimization of End-Milling Process Parameters Using Grey-Taguchi Approach Chitrasen Samantra*, Debasish Santosh Roy**, Amit Kumar Saraf***, & Bikash Kumar Dehury****, *Assistant Professor, Department of Mechanical Engineering, Gandhi Institute of Engineering and Technology, Gunupur, Rayagada Odisha, India **B.Tech Mechanical Students, Gandhi Institute of Engineering and Technology, Gunupur, Rayagada Odisha, India ***B.Tech Mechanical Students, Gandhi Institute of Engineering and Technology, Gunupur, Rayagada Odisha, India ****B.Tech Mechanical Students, Gandhi Institute of Engineering and Technology, Gunupur, Rayagada Odisha, India ABSTRACT The present work analyses different parameters of end milling to minimize the surface roughness for AISI D2 steel. D2 Steel is generally used for stamping or forming dies, punches, forming rolls, knives, slitters, shear blades, tools, scrap choppers, tyre shredders etc. Surface roughness is one of the main indices that determines the quality of machined products and is influenced by various cutting parameters. In machining operations, achieving desired surface quality by optimization of machining parameters, is a challenging job. In case of mating components the surface roughness become more essential and is influenced by the cutting parameters, because, these quality structures are highly correlated and are expected to be influenced directly or indirectly by the direct effect of process parameters or their interactive effects (i.e. on process environment). In this work, the effects of selected process parameters on surface roughness and subsequent setting of parameters with the levels have been accomplished by Taguchi’s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L16 orthogonal array. Experimental investigation of the end milling of AISI D2 steel with carbide tool by varying feed, speed and depth of cut and the surface roughness has been measured using surface roughness tester. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the contribution of the different process parameters on the process. Keywords: End milling process, Grey relational Analysis, Taguchi Approach.. 1. INTRODUCTION Milling is one of the most widely used metal removal processes in industry and milled surfaces are largely used to mate with other parts in die, aerospace, automotive, and machinery design as well as in manufacturing industries. Surface roughness is an important measure of the quality of a production and also influences the machining cost. The mechanism behind the formation of surface roughness is very dynamic, complicated, and