The present paper deals with experimental investigations carried out for machinability study of hardened steel and to obtain optimum process parameters by grey relational analysis. An orthogonal array, grey relations, grey relational coefficients and analysis of variance (ANOVA) are applied to study the performance characteristics of machining process parameters such as cutting speed, feed, depth of cut and width of cut with consideration of multiple responses, i.e. volume of material removed, surface finish, tool wear and tool life. Tool wear
patterns are measured using optical microscope and
analysed using scanning electron microscope and X-ray
diffraction technique. Chipping and adhesion are main
causes of wear. The optimum process parameters are
calculated for rough machining and finish machining using
grey theory and results are compared with ANOVA
