Marakini, V.Pai, S.P.Bhat K, U.K.Thakur, D.S.Achar, B.P.2026-02-042023Journal of Materials Engineering and Performance, 2023, 32, 6, pp. 2749-275710599495https://doi.org/10.1007/s11665-022-07187-4https://idr.nitk.ac.in/handle/123456789/22011In the present study, high-speed dry face milling is performed on AZ91 magnesium alloy using uncoated carbide inserts. The most influential surface integrity characteristics, such as surface roughness, hardness, microstructure and residual stresses, are investigated for a set of milling parameters chosen from the Taguchi design of experiments. The impact of machining conditions, such as feed rate, cutting speed and depth of cut on the surface integrity characteristics, are identified in order to improve the overall functionality of the alloy. Grey Relational Analysis optimization method is implemented to identify the optimal milling conditions. The results showed that high-speed dry face milling is very influential in improving the overall surface integrity characteristics of this alloy. © 2022, ASM International.CarbidesCuttingCutting toolsDesign of experimentsMagnesium alloysSpeedSurface roughnessAz91Az91 mg alloysCarbide insertsCutting speedDepth of cutDry face millingFeedrateHigh SpeedSurface integrityUncoated carbide insertMilling (machining)