Search results for: Taguchi%20method.

Authors: M. P. Chakravarthy, N. Ramanaiah, B. S. K.Sundara Siva Rao

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Taguchi approach was applied to determine the most influential control factors which will yield better tensile strength of the joints of pulse TIG welded 70/30 Cu-Ni alloy. In order to evaluate the effect of process parameters such as pulse frequency, peak current, base current and welding speed on tensile strength of Pulsed current TIG welded 70/30 Cu-Ni alloy of 5 mm thickness, Taguchi parametric design and optimization approach was used. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined at 95% confidence level. The results indicate that the Pulse frequency, peak current, welding speed and base current are the significant parameters in deciding the tensile strength of the joint. The predicted optimal values of tensile strength of Pulsed current Gas tungsten arc welding (PC GTAW) of 70/30 Cu-Ni alloy welds are 368.8MPa.

Keywords: 70/30 Cu-Ni alloy, pulsed current GTAW, mechanical properties, Taguchi technique, analysis of variance.

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Authors: Harish Kumar Ponnappan, Joseph C. Chen

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The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L₉ orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.

Keywords: Live tooling, surface roughness, Taguchi analysis, Computer Numerical Control (CNC) milling operation, CNC turning operation.

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Authors: Anjian Chen, Joseph C. Chen

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This paper studies a case where the targeted surface roughness of fused deposition modeling (FDM) additive manufacturing process is improved. The process is designing to reduce or eliminate the defects and improve the process capability index Cp and Cpk for an FDM additive manufacturing process. The baseline Cp is 0.274 and Cpk is 0.654. This research utilizes the Taguchi methodology, to eliminate defects and improve the process. The Taguchi method is used to optimize the additive manufacturing process and printing parameters that affect the targeted surface roughness of FDM additive manufacturing. The Taguchi L9 orthogonal array is used to organize the parameters' (four controllable parameters and one non-controllable parameter) effectiveness on the FDM additive manufacturing process. The four controllable parameters are nozzle temperature [°C], layer thickness [mm], nozzle speed [mm/s], and extruder speed [%]. The non-controllable parameter is the environmental temperature [°C]. After the optimization of the parameters, a confirmation print was printed to prove that the results can reduce the amount of defects and improve the process capability index Cp from 0.274 to 1.605 and the Cpk from 0.654 to 1.233 for the FDM additive manufacturing process. The final results confirmed that the Taguchi methodology is sufficient to improve the surface roughness of FDM additive manufacturing process.

Keywords: Additive manufacturing, fused deposition modeling, surface roughness, Six-Sigma, Taguchi method, 3D printing.

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Authors: Mohamed Zakaulla, A. R. Anwar Khan

Abstract:

Al6061 alloy base matrix, reinforced with particles of silicon carbide (10 wt %) and Graphite powder (1wt%), known as hybrid composites have been fabricated by liquid metallurgy route (stir casting technique) and optimized at different parameters like applied load, sliding speed and sliding distance by taguchi method. A plan of experiment generated through taguchi technique was used to perform experiments based on L27 orthogonal array. The developed ANOVA and regression equations are used to find the optimum coefficient of friction and wear under the influence of applied load, sliding speed and sliding distance. On the basis of “smaller the best” the dry sliding wear resistance was analysed and finally confirmation tests were carried out to verify the experimental results.

Keywords: Analysis of variance, dry sliding wear, Hybrid composite, orthogonal array, Taguchi technique.

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Authors: Joseph C. Chen, Joshua Cox

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This research focuses on the use of the Taguchi method to reduce the surface roughness and improve dimensional accuracy of parts machined by Wire Electrical Discharge Machining (EDM) with S7 heat treated steel material. Due to its high impact toughness, the material is a candidate for a wide variety of tooling applications which require high precision in dimension and desired surface roughness. This paper demonstrates that Taguchi Parameter Design methodology is able to optimize both dimensioning and surface roughness successfully by investigating seven wire-EDM controllable parameters: pulse on time (ON), pulse off time (OFF), servo voltage (SV), voltage (V), servo feed (SF), wire tension (WT), and wire speed (WS). The temperature of the water in the Wire EDM process is investigated as the noise factor in this research. Experimental design and analysis based on L₁₈ Taguchi orthogonal arrays are conducted. This paper demonstrates that the Taguchi-based system enables the wire EDM process to produce (1) high precision parts with an average of 0.6601 inches dimension, while the desired dimension is 0.6600 inches; and (2) surface roughness of 1.7322 microns which is significantly improved from 2.8160 microns.

Keywords: Taguchi parameter design, surface roughness, dimensional accuracy, Wire EDM.

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Authors: M. Hosseinzadeh, S. A. Zamani, A. Taheri

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During the last few years, several sheet hydroforming processes have been introduced. Despite the advantages of these methods, they have some limitations. Of the processes, the two main ones are the standard hydroforming and hydromechanical deep drawing. A new sheet hydroforming die set was proposed that has the advantages of both processes and eliminates their limitations. In this method, a polyurethane plate was used as a part of the die-set to control the blank holder force. This paper outlines the Taguchi optimization methodology, which is applied to optimize the effective parameters in forming cylindrical cups by the new die set of sheet hydroforming process. The process parameters evaluated in this research are polyurethane hardness, polyurethane thickness, forming pressure path and polyurethane hole diameter. The design of experiments based upon L9 orthogonal arrays by Taguchi was used and analysis of variance (ANOVA) was employed to analyze the effect of these parameters on the forming pressure. The analysis of the results showed that the optimal combination for low forming pressure is harder polyurethane, bigger diameter of polyurethane hole and thinner polyurethane. Finally, the confirmation test was derived based on the optimal combination of parameters and it was shown that the Taguchi method is suitable to examine the optimization process.

Keywords: Sheet Hydroforming, Optimization, Taguchi Method

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Authors: Weinian Wang, Joseph C. Chen

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The objective of this research is to optimize the process of cutting cylindrical workpieces utilizing live tooling on a HAAS ST-20 lathe. Surface roughness (Ra) has been investigated as the indicator of quality characteristics for machining process. Aluminum alloy was used to conduct experiments due to its wide range usages in engineering structures and components where light weight or corrosion resistance is required. In this study, Taguchi methodology is utilized to determine the effects that each of the parameters has on surface roughness (Ra). A total of 18 experiments of each process were designed according to Taguchi’s L9 orthogonal array (OA) with four control factors at three levels of each and signal-to-noise ratios (S/N) were computed with Smaller the better equation for minimizing the system. The optimal parameters identified for the surface roughness of the turning operation utilizing live tooling were a feed rate of 3 inches/min(A3); a spindle speed of 1300 rpm(B3); a 2-flute titanium nitrite coated 3/8” endmill (C1); and a depth of cut of 0.025 inches (D2). The mean surface roughness of the confirmation runs in turning operation was 8.22 micro inches. The final results demonstrate that Taguchi methodology is a sufficient way of process improvement in turning process on surface roughness.

Keywords: Live tooling, surface roughness, Taguchi Parameter Design, CNC turning operation.

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Authors: S. B. V. S. P. Sastry, V. V. S. Kesava Rao

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In this paper, x-ray impact of Taguchi method and design of experiment philosophy to project relationship between various factors leading to output yield strength of rebar is studied. In bar mill of an integrated steel plant, there are two production lines called as line 1 and line 2. The metallic properties e.g. yield strength of finished product of the same material is varying for a particular grade material when rolled simultaneously in both the lines. A study has been carried out to set the process parameters at optimal level for obtaining equal value of yield strength simultaneously for both lines.

Keywords: Bar mill, design of experiment, Taguchi, yield strength.

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Authors: Krishna Mohana Rao, G. Ravi Kumar, P. Sowmya

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This paper presents a study of the Taguchi design application to optimize surface quality in damper inserted end milling operation. Maintaining good surface quality usually involves additional manufacturing cost or loss of productivity. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized, given various factors, using fewer resources than a factorial design. This Study included spindle speed, feed rate, and depth of cut as control factors, usage of different tools in the same specification, which introduced tool condition and dimensional variability. An orthogonal array of L9(3^4)was used; ANOVA analyses were carried out to identify the significant factors affecting surface roughness, and the optimal cutting combination was determined by seeking the best surface roughness (response) and signal-to-noise ratio. Finally, confirmation tests verified that the Taguchi design was successful in optimizing milling parameters for surface roughness.

Keywords: ANOVA, Damper, End Milling, Optimization, Surface roughness, Taguchi design.

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Authors: Thirasak Panyaphirawat, Pairoj Sapsmarnwong, Teeratas Pornyungyuen

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This paper presents the findings of an experimental investigation of important machining parameters for the horizontal boring tool modified to mouth with a horizontal lathe machine to bore an overlength workpiece. In order to verify a usability of a modified tool, design of experiment based on Taguchi method is performed. The parameters investigated are spindle speed, feed rate, depth of cut and length of workpiece. Taguchi L9 orthogonal array is selected for four factors three level parameters in order to minimize surface roughness (Ra and Rz) of S45C steel tubes. Signal to noise ratio analysis and analysis of variance (ANOVA) is performed to study an effect of said parameters and to optimize the machine setting for best surface finish. The controlled factors with most effect are depth of cut, spindle speed, length of workpiece, and feed rate in order. The confirmation test is performed to test the optimal setting obtained from Taguchi method and the result is satisfactory.

Keywords: Design of Experiment, Taguchi Design, Optimization, Analysis of Variance, Machining Parameters, Horizontal Boring Tool.

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Authors: J. Chen, N. Hundal

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Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.

Keywords: Surface roughness, taguchi parameter design, turning center, turn-milling operations, vertical machining center.

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Authors: S. Ghorbani, N. I. Polushin

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Chatter vibrations, occurring during cutting process, cause vibration between the cutting tool and workpiece, which deteriorates surface roughness and reduces tool life. The purpose of this study is to investigate the influence of cutting parameters and tool construction on surface roughness and vibration in turning of aluminum alloy AA2024. A new design of cutting tool is proposed, which is filled up with epoxy granite in order to improve damping capacity of the tool. Experiments were performed at the lathe using carbide cutting insert coated with TiC and two different cutting tools made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to design of experiment and to optimize cutting conditions. By the help of signal-to-noise ratio and analysis of variance the optimal cutting condition and the effect of the cutting parameters on surface roughness and vibration were determined. Effectiveness of Taguchi method was verified by confirmation test. It was revealed that new cutting tool with epoxy granite has reduced vibration and surface roughness due to high damping properties of epoxy granite in toolholder.

Keywords: ANOVA, damping capacity, surface roughness, Taguchi method, vibration.

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Authors: Sky Chou, Joseph C. Chen

Abstract:

This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index C_p and C_pk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L₉ orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Keywords: CNC machining, Six Sigma, Surface roughness, Taguchi methodology.

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Authors: Vladimir Aleksandrovich Rogov, Ghorbani Siamak

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Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbide cutting insert coated with TiC. Turning experiments were planned by Taguchi method L₉ orthogonal array.Three levels for spindle speed, feed rate, depth of cut and tool overhang were chosen as cutting variables. The obtained experimental data has been analyzed using signal to noise ratio and analysis of variance. The main effects have been discussed and percentage contributions of various parameters affecting surface roughness and natural frequency, and optimal cutting conditions have been determined. Finally, optimization of the cutting parameters using Taguchi method was verified by confirmation experiments.

Keywords: Turning, Cutting conditions, Surface roughness, Natural frequency, Taguchi method, ANOVA, S/N ratio.

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Authors: Joseph C. Chen, Venkata Karthik Jakka

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The main objective of this research is to optimize tensile strength and dimensional accuracy in injection molding processes using Taguchi Parameter Design. An L16 orthogonal array (OA) is used in Taguchi experimental design with five control factors at four levels each and with non-controllable factor vibration. A total of 32 experiments were designed to obtain the optimal parameter setting for the process. The optimal parameters identified for the shrinkage are shot volume, 1.7 cubic inch (A4); mold term temperature, 130 ºF (B1); hold pressure, 3200 Psi (C4); injection speed, 0.61 inch3/sec (D2); and hold time of 14 seconds (E2). The optimal parameters identified for the tensile strength are shot volume, 1.7 cubic inch (A4); mold temperature, 160 ºF (B4); hold pressure, 3100 Psi (C3); injection speed, 0.69 inch3/sec (D4); and hold time of 14 seconds (E2). The Taguchi-based optimization framework was systematically and successfully implemented to obtain an adjusted optimal setting in this research. The mean shrinkage of the confirmation runs is 0.0031%, and the tensile strength value was found to be 3148.1 psi. Both outcomes are far better results from the baseline, and defects have been further reduced in injection molding processes.

Keywords: Injection molding processes, Taguchi Parameter Design, tensile strength, shrinkage test, high-density polyethylene, HDPE.

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Authors: F. Salehuddin, I. Ahmad, F. A. Hamid, A. Zaharim, H. A. Elgomati, B. Y. Majlis, P. R. Apte

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In this study, the Taguchi method was used to optimize the effect of HALO structure or halo implant variations on threshold voltage (VTH) and leakage current (ILeak) in 45nm p-type Metal Oxide Semiconductor Field Effect Transistors (MOSFETs) device. Besides halo implant dose, the other process parameters which used were Source/Drain (S/D) implant dose, oxide growth temperature and silicide anneal temperature. This work was done using TCAD simulator, consisting of a process simulator, ATHENA and device simulator, ATLAS. These two simulators were combined with Taguchi method to aid in design and optimize the process parameters. In this research, the most effective process parameters with respect to VTH and ILeak are halo implant dose (40%) and S/D implant dose (52%) respectively. Whereas the second ranking factor affecting VTH and ILeak are oxide growth temperature (32%) and halo implant dose (34%) respectively. The results show that after optimizations approaches is -0.157V at ILeak=0.195mA/μm.

Keywords: Optimization, p-type MOSFETs device, HALO Structure, Taguchi Method.

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Authors: Navajyoti Panda, R. S. Pawar

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In this study, process parameters like punch angle, die opening, grain direction, and pre-bend condition of the strip for deep draw of high strength low alloy steel HSLA 420 are investigated. The finite element method (FEM) in association with the Taguchi and the analysis of variance (ANOVA) techniques are carried out to investigate the degree of importance of process parameters in V-bending process for HSLA 420&ST12 grade material. From results, it is observed that punch angle had a major influence on the spring-back. Die opening also showed very significant role on spring back. On the other hand, it is revealed that grain direction had the least impact on spring back; however, if strip from flat sheet is taken, then it is less prone to spring back as compared to the strip from sheet metal coil. HyperForm software is used for FEM simulation and experiments are designed using Taguchi method. Percentage contribution of the parameters is obtained through the ANOVA techniques.

Keywords: Bending, V-bending, FEM, spring-back, Taguchi, HyperForm, profile projector, HSLA 420 & St12 materials.

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Authors: M. K. Pradhan, Mayank Meena, Shubham Sen, Arvind Singh

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In this study, a multi objective optimization for end milling of Al 6061 alloy has been presented to provide better surface quality and higher Material Removal Rate (MRR). The input parameters considered for the analysis are spindle speed, depth of cut and feed. The experiments were planned as per Taguchis design of experiment, with L27 orthogonal array. The Grey Relational Analysis (GRA) has been used for transforming multiple quality responses into a single response and the weights of the each performance characteristics are determined by employing the Principal Component Analysis (PCA), so that their relative importance can be properly and objectively described. The results reveal that Taguchi based G-PCA can effectively acquire the optimal combination of cutting parameters.

Keywords: Material Removal Rate, Surface Roughness, Taguchi Method, Grey Relational Analysis, Principal Component Analysis.

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Authors: Parvinder S. Sandhu, Pavel Blecharz, Hardeep Singh

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Quantitative Investigation of impact of the factors' contribution towards measuring the reusability of software components could be helpful in evaluating the quality of developed or developing reusable software components and in identification of reusable component from existing legacy systems; that can save cost of developing the software from scratch. But the issue of the relative significance of contributing factors has remained relatively unexplored. In this paper, we have use the Taguchi's approach in analyzing the significance of different structural attributes or factors in deciding the reusability level of a particular component. The results obtained shows that the complexity is the most important factor in deciding the better Reusability of a function oriented Software. In case of Object Oriented Software, Coupling and Complexity collectively play significant role in high reusability.

Keywords: Taguchi Approach, Reusability, SoftwareComponents, Structural Attributes.

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Authors: Atul Dev, Pankaj Jha

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Dr. Genichi Taguchi looked at quality in a broader term and gave an excellent definition of quality in terms of loss to society. However the scope of this definition is limited to the losses imparted by a poor quality product to the customer only and are considered during the useful life of the product and further in a certain situation this loss can even be zero. In this paper, it has been proposed that the scope of quality of a product shall be further enhanced by considering the losses imparted by a poor quality product to society at large, due to associated environmental and safety related factors, over the complete life cycle of the product. Moreover, though these losses can be further minimized with the use of techno-safety interventions, the net losses to society however can never be made zero. This paper proposes an entirely new approach towards defining product quality and is based on Taguchi’s definition of quality.

Keywords: Existing concept, goal post philosophy, life cycle, proposed concept, quality loss function.

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Authors: Abolghasem Yazdani, Sara Pourjafar

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This study has applied the L16 orthogonal array of the Taguchi method to determine the optimized polymeric Nanocomposite asphalt binder. Three control factors are defined as polypropylene plastomer (PP), styrene-butadiene-styrene elastomer (SBS) and Nanoclay. Four level of concentration contents are introduced for prepared asphalt binder samples. all samples were prepared with 4.5% of bitumen 60/70 content. Compressive strength tests were carried out for defining the optimized sample via QUALITEK-4 software. SBS with 3%, PP with 5 % and Nanoclay with 1.5% of concentrations are defined as the optimized Nanocomposite asphalt binders. The confirmation compressive strength and also softening point tests showed that modification of asphalt binders with this method, improved the compressive strength and softening points of asphalt binders up to 55%.

Keywords: modified asphalt, Polypropylene, SBS, Nanoclay, Taguchi method

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Authors: Nripjit, Anand K Tyagi, Nirmal Singh

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The present work consecutively on synthesis and characterization of composites, Al/Al alloy A 384.1 as matrix in which the main ingredient as Al/Al-5% MgO alloy based metal matrix composite. As practical implications the low cost processing route for the fabrication of Al alloy A 384.1 and operational difficulties of presently available manufacturing processes based in liquid manipulation methods. As all new developments, complete understanding of the influence of processing variables upon the final quality of the product. And the composite is applied comprehensively to the acquaintance for achieving superiority of information concerning the specific heat measurement of a material through the aid of thermographs. Products are evaluated concerning relative particle size and mechanical behavior under tensile strength. Furthermore, Taguchi technique was employed to examine the experimental optimum results are achieved, owing to effectiveness of this approach.

Keywords: MMC, Thermographs, Tensile strength, Taguchi technique, Optimal parameters

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Authors: H. Abdizadeh, Y. Vahidshad

Abstract:

The present paper discusses the selection of process parameters for obtaining optimal nanocrystallites size in the CuOZrO2 catalyst. There are some parameters changing the inorganic structure which have an influence on the role of hydrolysis and condensation reaction. A statistical design test method is implemented in order to optimize the experimental conditions of CuO-ZrO2 nanoparticles preparation. This method is applied for the experiments and L16 orthogonal array standard. The crystallites size is considered as an index. This index will be used for the analysis in the condition where the parameters vary. The effect of pH, H2O/ precursor molar ratio (R), time and temperature of calcination, chelating agent and alcohol volume are particularity investigated among all other parameters. In accordance with the results of Taguchi, it is found that temperature has the greatest impact on the particle size. The pH and H2O/ precursor molar ratio have low influences as compared with temperature. The alcohol volume as well as the time has almost no effect as compared with all other parameters. Temperature also has an influence on the morphology and amorphous structure of zirconia. The optimal conditions are determined by using Taguchi method. The nanocatalyst is studied by DTA-TG, XRD, EDS, SEM and TEM. The results of this research indicate that it is possible to vary the structure, morphology and properties of the sol-gel by controlling the above-mentioned parameters.

Keywords: CuO-ZrO2 Nanoparticles, Sol-gel, Taguchi method.

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Authors: S. Heydari, H. Sharififard, M. Nabavinia, H. Kiani, M. Parvizi

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Rapid industrialization has led to increased disposal of heavy metals into the environment. Activated carbon adsorption has proven to be an effective process for the removal of trace metal contaminants from aqueous media. This paper was investigated chromium adsorption efficiency by commercial activated carbon. The sorption studied as a function of activated carbon particle size, dose of activated carbon and initial pH of solution. Adsorption tests for the effects of these factors were designed with Taguchi approach. According to the Taguchi parameter design methodology, L9 orthogonal array was used. Analysis of experimental results showed that, the most influential factor was initial pH of solution. The optimum conditions for chromium adsorption by activated carbons were found to be as follows: initial feed pH 6, adsorbent particle size 0.412 mm and activated carbon dose 6 g/l. Under these conditions, nearly %100 of chromium ions was adsorbed by activated carbon after 2 hours.

Keywords: Chromium, Adsorption, Taguchi method, Activated carbon.

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Authors: Yousef Amer, Mehdi Moayyedian, Zeinab Hajiabolhasani, Lida Moayyedian

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Moulded parts contribute to more than 70% of components in products. However, common defects particularly in plastic injection moulding exist such as: warpage, shrinkage, sink marks, and weld lines. In this paper Taguchi experimental design methods are applied to reduce the warpage defect of thin plate Acrylonitrile Butadiene Styrene (ABS) and are demonstrated in two levels; namely, orthogonal arrays of Taguchi and the Analysis of Variance (ANOVA). Eight trials have been run in which the optimal parameters that can minimize the warpage defect in factorial experiment are obtained. The results obtained from ANOVA approach analysis with respect to those derived from MINITAB illustrate the most significant factors which may cause warpage in injection moulding process. Moreover, ANOVA approach in comparison with other approaches like S/N ratio is more accurate and with the interaction of factors it is possible to achieve higher and the better outcomes.

Keywords: Analysis of variance, ANOVA, plastic injection mould, Taguchi methods, Warpage.

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Authors: Sahil Sharma, Mukesh Gupta, Raj Kumar, N. S Bindra

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This paper presents an experimental investigation on the optimization and the effect of the cutting parameters on Material Removal Rate (MRR) in Plasma Arc Cutting (PAC) of EN-45A Material using Taguchi L ₁₆ orthogonal array method. Four process variables viz. cutting speed, current, stand-off-distance and plasma gas pressure have been considered for this experimental work. Analysis of variance (ANOVA) has been performed to get the percentage contribution of each process parameter for the response variable i.e. MRR. Based on ANOVA, it has been observed that the cutting speed, current and the plasma gas pressure are the major influencing factors that affect the response variable. Confirmation test based on optimal setting shows the better agreement with the predicted values.

Keywords: Analysis of variance, Material removal rate, plasma arc cutting, Taguchi method.

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Authors: Naveen Beri, S. Maheshwari, C. Sharma, Anil Kumar

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In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.

Keywords: Electrical discharge machining (EDM), Powder Metallurgy (PM), Taguchi method, Material Removal Rate (MRR), Surface Roughness (SR).

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Authors: V.Sivaraman, S. Sankaran, L. Vijayaraghavan

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Machining through turning was carried out in a lathe to study the chip formation of Multiphase Ferrite (F-B-M) microalloyed steel. Taguchi orthogonal array was employed to perform the machining. Continuous and discontinuous chips were formed for different cutting parameters like speed, feed and depth of cut. Optical and scanning electron microscope was employed to identify the chip morphology.

Keywords: Multiphase microalloyed steel, chip formation, Taguchi technique, turning, cutting parameters

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Authors: D. V. Srikanth, M. Sreenivasa Rao

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Abrasive Jet Machining is an Unconventional machining process in which the metal is removed from brittle and hard material in the form of micro-chips. With increase in need of materials like ceramics, composites, in manufacturing of various Mechanical & Electronic components, AJM has become a useful technique for micro machining. The present study highlights the influence of different parameters like Pressure, SOD, Time, Abrasive grain size, nozzle diameter on the Metal removal of FRP (Fiber Reinforced Polymer) composite by Abrasive jet machining. The results of the Experiments conducted were analyzed and optimized with TAGUCHI method of Optimization and ANOVA for Optimal Value.

Keywords: ANOVA, FRP Composite, AJC.

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Authors: Sky Chou, Joseph C. Chen

Abstract:

This paper focuses on using six sigma methodologies to reach the desired shrinkage of a manufactured high-density polyurethane (HDPE) part produced by the injection molding machine. It presents a case study where the correct shrinkage is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for an injection molding process. To improve this process and keep the product within specifications, the six sigma methodology, design, measure, analyze, improve, and control (DMAIC) approach, was implemented in this study. The six sigma approach was paired with the Taguchi methodology to identify the optimized processing parameters that keep the shrinkage rate within the specifications by our customer. An L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of the cooling time, melt temperature, holding time, and metering stroke. The noise factor is the difference between material brand 1 and material brand 2. After the confirmation run was completed, measurements verify that the new parameter settings are optimal. With the new settings, the process capability index has improved dramatically. The purpose of this study is to show that the six sigma and Taguchi methodology can be efficiently used to determine important factors that will improve the process capability index of the injection molding process.

Keywords: Injection molding, shrinkage, six sigma, Taguchi parameter design.

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