Papers by Keyword: Orthogonal Array

Abstract: UD. Pak Suandi is one of the UDs that produces and sells bricks. Many factors influence the quality of bricks, namely human resources, composition, and processing of raw materials. Brick making sometimes does not match the desired quality, there are often defects/cracks in the bricks. The method used in this research is the Taguchi method, where Taguchi is used to design efficient and effective experiments in identifying factors that influence brick quality, such as brick compressive strength, as well as to determine optimal settings of production parameters with the aim of maximizing brick quality. The results of this research show that the factors that have a significant influence are factors A (Clay) and D (Laban Tree Ash). The high SNR ANOVA value shows this. The optimal concentration settings are 1.40 kg of Clay, 45 ml of Water, 13 grams of Palm Ash and 14 grams of Laban Tree Ash. Where with the composition design, a compressive strength value of 9.73 MPa is obtained. The compressive strength obtained increased by 6.03 Mpa from the company's standard composition of 3.70 Mpa.

Abstract: In high strength aluminium alloy material turning operation, high material removal and good surface are desirable output characteristics. In this investigation, experiments were conducted according to design of experiments concept with a combination of turning input parameters such as cutting speed, feed rate and depth of cut and also studied the effect of process parameters on multi outputs for machining of Al2024 aluminium alloy. Grey relation analysis was applied to know the robust process parameters. The contribution each parameter was realized with analysis of variance statistical method. The cutting speed is the most influencing parameter with contribution of 62.3% followed by depth of cut with 26.4%, and feed rate with 9.9%.

Abstract: Surface finish plays an important role in making quality products in the manufacturing sector. A turning experiment is conducted by cutting tool of nose radii (1 mm and 0.65 mm) to find its influence on surface roughness. Eight experiments were performed with Taguchi’s Orthogonal Array (OA) technique. The prime objective was to investigate the tool nose radius effects in the prediction of the optimum value of surface roughness. Cutting speed (V), feed (F), depth of cut (D), and tool nose radius (NR) were selected for the experimental work having two levels each. To find out the influential parameters analysis of variance (ANOVA) was carried out. Signal to noise ratio and average performance graph was analyzed to obtain optimum response values. The results concluded that the large nose radius develops a superior finish in comparison to the smaller one.

Abstract: The most common and serious defect in casting is porosity, which is the result of two phenomena namely, insufficient feeding and hydrogen precipitation during solidification. Formation of porosity defect in aluminum alloy is a complex process. Researchers have modeled the pore formation using analytical solution, criteria function and heat transfer simulations. Each model has its own advantages and disadvantages. This paper review the various papers which deals the models based on orthogonal array, Niyama criteria and GA/ANN.

Abstract: Production cost is dependent on the life of the Tool. Because of enormous heat generation during the material removal process, life of the tool decreases. Tool life will be enhanced by cryogenic treatment which minimises the temperature at tool tip interface. Taguchi technique was employed to get optimum number of experiments for turning white cast iron after the cryogenic treatment and before cryogenic treatment. The correlation between four main factors such as speed, feed, depth of cut, tool condition and responses such as surface roughness, tool tip temperature were analysed. Mathematical model was formulated for tool tip temperature, and surface roughness. The error for the mathematically formulated model was observed to be less than 5%.The present work indicates that cryogenically treated tool have better surface finish . From the anova analysis it is inferred that tool tip temperature and surface roughness substantially reduced while using cryogenically treated tool. It was observed that cutting forces was more influenced by cutting speed of the tool followed by tool condition. Hardness of the tool insert showed improvement because of coatings.

Abstract: This paper embarks the machining parameters of Turning by optimization using Taguchi’s approach. The optimization is very essential in order to obtain the expected surface quality. The results of cutting parameters of optimization is seen in the Surface Roughness, Tool wear and MRR of the material. The L18 Orthogonal array has been chosen for the optimization of Valve Steel SUH03.The uncoated carbide inserts were used and the four parameters Speed, Feed, Depth of Cut and Nose Radius has been taken as input parameters. The Signal to Noise ratio and Analysis of Variance software has been analyzed using Minitab software through which the optimal cutting parameters of the best surface roughness, tool wear and MRR has been obtained. The final results have been compared by the Gray relational analysis to find the optimum machining conditions of all the parameters.

Abstract: This paper presents an ideal approach for the optimization of machining parameters on turning of AA6061 T6 aluminium alloy with multiple responses based on orthogonal array with desirability function analysis. In this study, turning parameters namely cutting speed, feed rate and depth of cut are optimized with the considerations of multiple responses such as surface roughness (R_a), roundness (Ø) and material removal rate (MRR). Multi response optimization of machining parameters was done through desirability function analysis. The optimum machining parameters have been identified by a composite desirability value obtained from desirability function analysis. The performance index and significant contribution of process parameters were determined by analysis of variance.

Abstract: In drilling and boring process, the relief in clamping stress causes deformations that cause variations in the geometry of the drilled hole. In automobile industry, when such holes are used to hold gear systems or rods in place, this variation in geometry leads to poor fitting and subsequent failure. To avoid this, high level accuracy is required which is both expensive and time-consuming. Therefore, a high percentage of such drilled parts are rejected in industry. The present paper addresses this problem by characterizing the variations in hole geometry as a function of clamping force, hole diameter, hole eccentricity (distance of hole-center from center of drilled face) and angular position of hole with respect to clamp location. The analysis result quantifies the comparative effect of each aforementioned factor on hole geometry variation. Taguchi Method based Design of Experiments using L25 orthogonal array has been used for performing the parametric design to arrive at the best settings of the 4 parameters. The optimal settings minimize ovality and displacement of the hole-center, and thus increase hole-fitting and its reliability against manufacturing variability.

Abstract: Epoxy is blended with metal fillers to enhance its performance and application for tooling. Material used contains aluminium particles (Rencast CW47), blended with brass separately. Brass is added into the matrix based on 10%, 20% and 30% of the epoxy mix weight ratio. Using Taguchi method, controls factor such as pre-curing temperature (A), filler percentage (B), degassing time (C), curing time (D) and post curing temperature (E) are selected parameters in order to determine optimum conditions. Noise strategy is adopted for material cooling via ambient (N1) and oven temperatures (N2), which gave different hardness values of the epoxy composite. Optimum parameters were decided based on the prediction of S/N ratio, where A = Room temperature, B = 20%, C = 60 minutes, D = 14 hours and E = 1800C. The most significant control factor is de-gassing time for both fillers, and percentage of filler to weight ratio of epoxy mixture is optimum at 20%. It was found that brass gave higher mean hardness values, (Hv = 24.1) compared to copper (Hv = 22.7) and aluminium filled epoxy (Hv = 22.3) based on the prediction run, and suitable as additional filler to improve the surface toughness of epoxy matrix as inserts. Confirmation run was conducted according to the optimum parameters and validated the gain values for brass at 7.98. Fillers enhance the mechanical properties of epoxy matrix by increasing hardness of mould cavity and core. This work helped to design the best control factors to produce optimum hardness conditions for filled epoxy matrix.

Abstract: Quality control is important aspect of manufacturing process. The quality of product in injection moulding is influenced by injection moulding process parameter. A study of the influence of process parameters on the injection moulding process is presented. Statistically based model approach were studied. In this the process parameter that affect the injection moulding process are like injection time, injection pressure, packing pressure, packing time, cooling time, coolant temperature mold temperature, melt temperature are studied and compared. This paper deals with design of experiment approach to fine out optimal parameter setting. The comparison shows effect of parameters on injection moulding process.Key words: Plastic injection moulding, Orthogonal array, Cycle time