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Taguchi PDF
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ABSTRACT
Metal matrix composites (MMCs) are now investigated the electrochemical micromachining
gaining their usage in aerospace, automotive and through response surface methodology approach by
biomedical industries because of their inherent taking MRR and ROC as separate objective
properties like high strength to weight ratio, low measures, developed mathematical models and
wear rate etc. To machine these types of materials analyzed with reference to machining parameters [2].
conventional machining methods are unsuitable P.S. Kao et al. investigated the electrochemical
because of high tool wear and tooling cost. polishing of stainless steel by grey relational analysis
Electrochemical Machining (ECM) is one of the by taking surface roughness and passivation strength
important non-traditional machining processes, of electrolyte as responses [3]. Modeling of the ECM
which is used for machining of electrically has done by using fuzzy logics and evolutionary
conducting, difficult-to-machine materials and algorithms by taking current, voltage, gap and feed
intricate profiles. In the present work LM6 rate as process parameters and MRR and surface
Al/5%SiC composites, which are fabricated by roughness as responses [4, 5]. P. Asoken et al.
stir casting route, were machined by ECM developed multiple regression and Artificial Neural
process. The influence of the various process Network (ANN) models for optimizing the
parameters, i.e. voltage, feed rate and electrolyte electrochemical process parameters like voltage,
concentration on the predominant machining current, gap and feed rate [6]. D. Chakradhar et al.
criteria, i.e. the metal removal rate (MRR) was developed the multi-objective optimization models
studied. The settings of the process parameters for electrochemical machining by grey relational
were determined by using Taguchi’s experimental analysis while machining EN31 steel with electrolyte
design method. Orthogonal arrays of Taguchi, the concentration, feed rate and voltage as process
signal-to-noise (S/N) ratio, the analysis of variance parameters [7]. C. senthilkumar et al. developed
(ANOVA), and regression analyses are employed mathematical models for ECM based on Response
to find the optimal process parameter levels and Surface Methodology (RSM) for LM25 Al/10%SiC
to analyze the effect of these parameters on metal composites [8]. S. J. Ebeid et. al. developed
removal rate values. Confirmation test with the mathematical models for correlating the inter
optimal levels of machining parameters was relationships of various machining parameters such
carried out in order to illustrate the effectiveness as voltage, feed rate, back pressure and vibration
of the Taguchi optimization method. amplitude on over cut and conicity for achieving
high controlled accuracy [9].
Keywords – LM6 Al/ SiC composites, Stir casting, In this study, LM6 Al/5%SiC composites were
Electrochemical Machining, Material Removal fabricated by stir casting method and machined on
Rate, Taguchi optimization methods, ANOVA. ECM process. The settings of ECM process
parameters were determined by using Taguchi’s
I. INTRODUCTION experimental design method. Orthogonal arrays of
ECM is the one of the non-conventional machining Taguchi, the signal-to-noise (S/N) ratio, the analysis
process used for machining high-strength, heat of variance (ANOVA), and regression analyses are
resistant, extremely hard materials into complex employed to find the optimal levels and to analyze
shapes. ECM is a process based on the controlled the effect of the ECM process parameters on metal
anodic dissolution process of the work piece as removal rate values. Confirmation test with the
anode, with the tool as cathode in an electrolytic optimal levels of machining parameters was carried
solution. Its industrial applications have been out in order to illustrate the effectiveness of
extended to electrochemical drilling, grinding, Taguchi’s optimization method.
deburring and polishing [1]. Jagannath Munda et al.
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Rama Rao. S, Padmanabhan. G / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
B. Experimental Details
The experiments were conducted on METATECH V. RESULTS AND ANALYSIS OF EXPERIMENTS
ECM equipment which is shown in Fig 2. The ECM
setup consists of control panel, machining chamber, A. Regression Analysis
electrolyte circulation system. The workpiece is fixed The applied voltage, feed rate and electrolyte
inside the chamber and tool is attached to the main concentration were considered in the development of
screw which is driven by a stepper motor. For mathematical models for the metal removal rate. The
avoiding short-circuits, a current sensing circuit is correlation between factors (applied voltage, feed
interfaced between the tool and the steeper motor rate and electrolyte concentration) and metal removal
controller circuit. If the current exceeds an acceptable rate on the LM6 Al/5%SiC composite were obtained
limit, a signal is sent to the stepper motor controller by multiple linear regressions.
circuit which immediately reverses the downward
motion of the tool. The process parameters like The standard commercial statistical software
current, voltage and feed rate are varied by the package MINITAB was used to derive the models of
control panel. The electrolyte is pneumatically the form:
pumped. The tool was made up of copper with a Metal removal rate (MRR) = -0.00349 +
circular cross section of 12mm diameter with 2mm 0.00315*A + 0.165*B + 0.000595*C (3)
internal hole. The tool was coated with a layer of
200µm epoxy powder resin, except for the base of R2=0.996
194 | P a g e
Rama Rao. S, Padmanabhan. G / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Table 4 MRR values and S/N ratio values for Fig. 5 Effect of process parameters on MRR
experiments
The effect of process parameters on the metal
Exp. No. MRR value S/N ratio (dB) removal rate values was shown in Fig. 5. The MRR
(g/min) increases with increasing in voltage, feed rate and
1 0.0559 25.0518 electrolyte concentration. According to the Faraday’s
2 0.0789 22.0585 law MRR is proportional to the machining current.
The increase in machining voltage causes a greater
3 0.1023 19.8025
machining current in the electrode gap, thereby
4 0.0765 22.3268 causing the enhancement of the MRR. With the
5 0.0987 20.1137 increase in electrolyte concentration, the larger
number of ions associated with the machining
195 | P a g e
Rama Rao. S, Padmanabhan. G / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Source of Degrees of Sum of Variance (V) F-ratio (F) P-value (P) Percentage
variation freedom squares (S) (%)
(DOF)
196 | P a g e
Rama Rao. S, Padmanabhan. G / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
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