Process Standardization

Process Standardization through Taguchi Design of Experiments

Lean tool - standardization eliminates variation and incorrect assumptions in the way that work is performed. The resent work involves standardization of process parameter for a electrical discharge machine through Taguchi design of experiment there by reducing the variation between parts in the process. Through conducting experiments optimum levels are identified for the materials EN8, EN353 and EN24 are explained in this present work. Standardization is achieved through finding the optimum levels for each material and communicating the findings through standard operating procedures (SOP). The project starts with the study of the process (EDM), Taguchi design of experiment, regression analyses and optimization methods.

4.1 Electrical Discharge Machining The basic concept of electrical discharge machining is cratering out of metals affected by the sudden stoppage of the electrical beam by the solid metal surface of the anode. The portion of the anode facing the direct electrical pulse reaches the boiling point. Even in the case of median long pulse the rate of temperature increase in tens of millions of degree per second which means dealing with explosion process. The shock wave produced spreads from the center of the explosion inside the metal and on the way crush the metal and deforms crystal. When a suitable unipolar (pulsed) voltage is applied across two electrodes separated by a dielectric fluid, the later breaks down. The electrons, so liberated, are accelerated in the presence of the electric field collide with the dielectric molecules, causing the later to be robbed off their one or two electrons each and immunize. The process grows and multiplies the second emission followed by an avalanche of electrons and ions. The resistant of the dielectric layer drops as it is ionized result in ultimate break down. The electrical energy is
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discharged into the gap and multifarious action takes place electrodynamics waves set in and travels at speed causing shock-impact and high temperature rise at the electrode surface. The instantaneous temperature may rise as high as 1000 oc causing localized vaporization of the electrode.

Servo head Working tank

Power supply

Dielectric reservoir Hand wheel Tool (Cathode)

+
Work Piece (anode)

Dielectric

Figure 4.1 block diagram of EDM process The electrical discharge machining process involves finite discrete periodic sparks between tool electrode and conductive work-electrode separated by a thin film of dielectric that causes removal of work material. 4.1.2 High temperature theory According to this theory, due to the bombardment of the high energetic electrons on the electrode surface, the spot attains high temperature (100,00 oc) especially with material of low thermal conductivity. At this temperature, material at that spot instantaneously melts and vaporizes leaving a crater on the surface.

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4.2 Taguchi Design of Experiments Taguchi method was designed to improve the quality of product and process where the performance depends on many factors. In laying out a test and development strategy, simple logic will usually be sufficient to establish all possible combination of factors along with allowable range of each of the factors involved. But the engineering projects involving many factors, the number of possible combination is prohibitively large. To reduce the number of experiments to a practical level, only a small set from all possibilities, is selected. The method of selecting the limited number of experiment which produces the most information is known as a partial factorial experiment. Taguchi constructed a special set of general design for fractional experiments that covers many applications. The special set of designs consists of orthogonal arrays. The use of this orthogonal array helps to determine the least number of experiments needed to a given set of factors. The combination of standard experimental design techniques and analysis methods in the Taguchi approach produces consistency and reproducibility. Taguchi experimental results is primarily to seek the answers to the following three questions 1. What is the optimum condition? 2. Which factors contribute to the result and by how much? 3. What will be the expected result at the optimum condition? 4.2.1 Taguchis philosophy involves three central ideas 1. Products and processes should be designed so that they are robust to external

source of variability. 2. Experimental design methods are engineering tools that help this objective. 3. The operation on target is more important than conformance to specifications.

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Figure4.2 The Design of Experiment Process

4.3 Regression Analysis Chi Square test tells us whether there is any relationship between variables but it does not tell us, what the relationship is. Regression analysis shows us how to determine both the nature and strength of relationship between two variables. So regression analysis serves as a efficient model building technique.

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Figure 4.3 Procedure for building the regression model 4.3.1Least square method A good fit is required for minimize the error and to establish the regression line as a mathematical model. The least square method statistically proves it efficiency by maintaining the lowest error. Least square method fits the data distribution on a line with minimum error.

Estimating Equation Describing Relationship among three variables

= Estimate value corresponding to the dependant variable. a = Y- intercepts

X1, X2 = Values of the dependant variables b1, b2 = Slope associated with X1, X2 respectively

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Normal equation

Solving the normal provides the value of the Y intercepts and the slopes of the variables. Using calculated data dependant variable is estimated.

4.3 Methodology The methodology adopted to carry out the project is by Taguchis design of experiment technique. Taguchi has suggested a new approach for design of experiments, which identifies the nature of parameters by conducting minimum number of experiments and which is extensively applicable in manufacturing industries. Taguchis approach will give a clear idea about the most influencing parameters on surface finish. The objective of the research is an experimental investigation to find optimization of machining parameters of EDM machine for machining steel material EN-353 using Taguchis DOE. Another point made to optimize the machining parameters for EDM is to achieve maximum surface finish. The parameters considered are pulse on time, Pulse off time, Peak current and gap voltage. Then the Regression aids us to build the mathematical model and the model is used to generate optimized solution using steepest descent method.

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4.3.1 Experimental Setup An EDM machine Electronica PSR 35 is used for conducting the experiment. The work material electrode and the other machining conditions are as follows: 1. Work piece steel material En-353 (Anode). 2. Work piece height is 30 mm. 3. Hardness of the work piece material is 50HRC. 4. Electrode copper round rod of 50 mm diameter (Cathode) 5. Average voltage gap 45 to 55 volts by adjusting servo feed setting during machining.
6. Di- electric temperature is 22 to 25C. 7. Flushing pressure of die-electric fluid is 13 to 15 kg/cm2.

Four machining parameter such as pulse on-time, pulse off-time, peak current and gap voltage are considered as controlling factors and each parameter has three levels. 4.3.2 Experimental Result In this experimental study, 4 factors and 3 levels are used and L9 orthogonal array suitable for this experimental design was selected. The completed design with description of factors and their levels and the orthogonal array are shown in Table 4.1. Table 4.1 Column 1 2 Factors Pulse time Pulse Units on -sec off -sec Design factors and their levels Level -1 25 10 Level -2 50 15 Level -3 75 20 7 55

time 3 Peak current Amps 3 5 4 Gap voltage Volts 45 50 Note: Interactions between the factors are not considered.

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Table 4.2 Trial Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Trial 6 Trial 7 Trial -8 Trial 9 1 1 1 1 2 2 2 3 3 3

L9 Orthogonal array used for the experiment 2 1 2 3 1 2 3 1 2 3 3 1 2 3 2 3 1 3 1 2 4 1 2 3 3 1 2 2 3 1

Objective: Determine best machining parameters in EDM. Characteristics- Smaller is better.

Table 4.3 Trial / Repetitions 1 2 3 4 5 6 7 8 9 R1 2.6 1.9 2.5 2.8 3.4 3.1 3.3 2.8 3.1

Original observation and their average R2 2.7 2.0 2.3 3.0 3.6 3.3 3.7 2.9 3.2 R3 2.5 2.1 2.7 3.1 3.7 3.3 3.3 3.1 3.4
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R4 2.6 2.0 2.5 2.7 3.3 3.1 3.3 3.2 3.5

Average 2.6 2.0 2.5 2.9 3.5 3.2 3.4 3.0 3.3

Process Standardization

Quality characteristics: Smaller is better. Result: Up to 4 repetitious shown. Table 4.4 Column 1 2 3 4 Factors Pulse time Pulse Level -1 on 2.366 off 2.966 2.933 3.133 Main effect Level -2 3.2 2.833 2.733 2.866 Level -3 3.233 3 3.133 2.799 L2 L1 .834 -0.134 -0.2 -0.267

time Peak current Gap voltage

Mai n Effects P l ot for M eans

Data Means
PULSE ON TIME 3.2 3.0 2.8 PULSE OFF TIME

Mean of Means

2.6 2.4 25 3.2 3.0 2.8 2.6 2.4 3 5 7 45 50 55 50 PEAK CURRENT 75 10 15 GAP VOLTAGE 20

Table 4.5 Column

Figure 4.4 mean effect chart (EN353) ANOVA table(353) Factors Dof (f) Sum squares of Variance (V) F ratio Percent P%

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1 2 3 4 Other error Total Column 1 2 3 4

Pulse time Pulse time Peak

on 2 off 2 2 2 0 8

(S) 1.446 0.046 0.239 0.186

0.723 0.023 0.119 0.093

(F) -

75.343 2.43 12.499 9.721 100

current Gap voltage Table 4.6 Factors Pulse on time Pulse off time Peak current Gap voltage

1.92 Optimum conditions and performance Level description 25 15 5 55 Level 1 2 2 3

Contribution -.567 -.101 -.2 -0.134

Contribution from all the factors (Total) - 1.002 Current grand average of performance 2.933 Expected result at optimum condition 1.931 Nine work pieces EN-353 round rod diameter 45mm top surface were machined in EDM by using electrode copper diameter 50mm. Each sample was measured for surface roughness by using TAYLOR-HABSON Surtonic 3 surface roughness measuring equipment. Since longer life was desirable, the quality characteristic applicable in this case was Smaller is better. The main effect was shown in (Table 4.4). The study of the main effects indicates some interaction between the factors. Percentage contribution for EN-353 materials was shown in (Table 4.5) and from this the significant factor, which is having more influence for surface finish was obtained. In this experiment, the result of the contribution in the order of Pulse on time (75.34%), Peak current (12.5%), Gap voltage (9.72%) and pulse off time (2.43%).

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The purpose of the ANOVA is to investigate which parameters significantly affect the performance characteristics. The result of the ANOVA (Table4.5) indicates that pulse ontime, Peak current, Gap voltage, and Pulse off time are the significant machining parameters and the percentage contribution in the order of 75.343%, 12.499%, 9.721%, and 2.43%. In the ANOVA table, the factor assigned column has the smallest sum of squares and hence the least influence. It is proved from the ANOVA (Table 4.5), the factor assigned to the column (2) has the smallest sum of squares (0.046) and hence the least influence. Confirmation test was conducted at the following levels and the factors and its surface roughness value is measured and found as 2.1.

Table 4.7

Optimum conditions Ra for EN-353 material Peak current 5 Gap voltage 55

Trial No Pulse on time Pulse off time 1 25 15 Confirmation experiment result 2.1 micron.

Expected result at optimum condition 1.931 micron. A key component of Taguchis philosophy is reduction of variability. It often requires that each quality as a target or nominal value. The objective is to reduce the variability around this target. In this experiment the difference between the results is very minimum such as 0.169 micron. In this experimental value, Taguchis philosophy is satisfied. 4.3 Regression analysis Regression analysis was carried out using Minitab 15 the results are summarized below The regression equation is Ra = 3.43 + 0.0173 PULSE ON TIME + 0.0033 PULSE OFF TIME + 0.0500 PEAK CURRENT - 0.0333 GAP VOLTAGE

S = 0.375832 R-Sq = 70.6% R-Sq(adj) = 41.1%

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4.6 Standard operating parameter To serve the purpose of standardization the optimum levels are communicated to the shop floor through work instruction by standard operating procedure. The list of standard operating parameter are presented in the (Table 4.8). Table 4.8 Standard operating parameters material\Parameters EN 8 EN 24 EN 353 Peak Current Pulse of Pulse on time Gap voltage time 3 25 50 3 25 45 5 25 55

15 15 15

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