| Summary: | This paper presents the use of TOPSIS, a multi-criteria decision-making model combined with the Taguchi method to find the optimum milling parameters. TOPSIS is the Technique for Order Preference by Similarity to the Ideal Solution and shows the value of closeness to the positive ideal solution. This study shows the optimum combination of process parameters using the shortest distance from the ideal solution. The surface roughness and flank tool wear were considered the objectives for simultaneous optimization. After converting multiple responses into a single response, the Taguchi method was used to analyze and determine the optimum machining parameters. According to reported studies, the initial wear behavior and initial cutting conditions have significant effects on the tool wear progress. Several initial cutting parameters can contribute to tool life and therefore can be used to improve both tool life and surface roughness. However, the cutting speed may significantly affect tool wear and ultimate tool life. In this study, an innovative solution was proposed for interrupted machining with two different cutting speeds. The first level cutting speed was used for 1 s and the second level was used for the rest of the process. The experimental results indicate that the initial speed followed by the feed rate significantly affects tool life. In addition, using the proposed strategy with different levels of cutting speed during machining operations led to improved tool life and surface roughness compared to conventional machining with uniform cutting speed throughout the entire process.
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