Implimentation of Taguchi method on CNC EDM and CNC WEDM

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Implimentation of Taguchi method on CNC EDM and CNC WEDM

  1. 1. By,KIRAN H GRAGHUNANDAN H SRAJESH SVINITESH K V
  2. 2. ABS KEYWORDS: CNC EDM, CNC WEDM, Taguchi method, DOE,T Orthogonal arrayRACT
  3. 3. INTRODUCTIONC DESIGN OF EXPERIMENTO TAGUCHI METHODN EXPERIMENTRAL AND SLECTIONT OF PROCESS PARAMETERSE EXPERIMENTRAL OBSERAVATIONN EXPERIMENTRAL RESULTS AND ANALYSIS TAGUCHI METHODT CONCLSIONS REFERENCES
  4. 4. INTRODUCTIONEDM is an electro-thermal non-traditional machiningprocess, where electrical energyis used to generate electricalspark and material removalmainly occurs due to thermalenergy of the sparkThe work material isremoved by a series of sparksthat cause localized meltingand evaporation of thematerial EDNC 32H MAKINO high precision CNC EDM
  5. 5. EDM is mainly used to machine difficult-to-machine materials.The electrode is made from electrically conductivematerial. EDNC 32H MAKINO high precision CNC EDMDielectric fluid should be nonconductor of electricity
  6. 6. WIRE CUT ELECTRODISCHARGE MACHINING(WEDM),WEDM is electro-thermalmechanisms to cut electricallyconductive material.WEDM has become theessential part of manymanufacturing processindustries, which need variety,precision and accuracy FA10S MITSUBISHI high precision CNC WEDM
  7. 7. DESIGN OF EXPERIMENT Design of Experiments (DOE) refers to planning, designingand analyzing an experiment so that valid and objectiveconclusions can be drawn effectively and efficiently. The input variables are called Factors and the outputvariables are called Response.
  8. 8. THE ADVANTAGES OF DESIGN OF EXPERIMENTS ARE Numbers of trials is significantly reduced. Optimal setting of the parameters can be foundout. Qualitative estimation of parameters can be made. Experimental error can be estimated. Inference regarding the effect of parameters onthe characteristics of the process
  9. 9.  Dr. Genichi Taguchi wasDR. GENICHI TAGUCHI Born in Japan, 1924. He is an Electrical Engineer and Worked during 1950’s to improve Japan’s post-WWII telephone communication system And also called Father of the “Taguchi Method” and “Robust Engineering
  10. 10. HE SUGGESTED THATTHE DESIGN PROCESSSHOULD BE SEEN ASTHREE STAGES • SYSTEM DESIGN1 • PARAMETER2 DESIGN • TOLERANCE3 DESIGNIn this present work, the Taguchi method has been used toplan the experiments for parameter design and subsequentanalysis of the data collected
  11. 11. PARAMETER DESIGN Parameter design determines the most appropriate, optimizing set of parameters identifying the settings of each parameter which will minimize variation from the target performance The selection of control factors (parameters) and their “OPTIMAL” levels The objective is to make the “IMPROVEMENT OF QUALITY” The “ OPTIMAL ” parameter levels can be determined through experimentation
  12. 12. INITIATING STEPS 2. BRAIN 3. STORMING EXPERIMENTAL SESSION DESIGN 1. PROBLEM (Identify:- FactorsIDENTIFICATION ,Factors settings , (Choose orthogonal Possible Interaction arrays, Design , Objectives) Experiment )
  13. 13. 4. RUN EXPERIMENT 5. ANALYZE RESULTS 6.CONFIRMATION RUNS
  14. 14. EXPERIMENTRAL AND SLECTION OF PROCESS PARAMETERS FOR CNC EDMINPUT FACTORS FOR CNC EDM1) VOLTAGE (V)2) CURRENT (I)3) PULSE ON TIME (TON)RESPONSES MEASURED FOR EDM1) MATERIAL REMOVAL RATE (MRR),2) MACHINING TIME
  15. 15. TABLE 1:- LEVEL VALUES OF INPUT FACTORSymbols Testing parameters Level1 Level2 Level3 A Voltage (V) 6 7 5 B Current(I) 2 3 4 C Pulse ON time(Ton) 35 40 45 Array Selector
  16. 16. ORTHOGONAL ARRAYSOrthogonal Arrays represent a versatile class ofcombinational arrangements useful for conductingexperiments. The standard two level and three level arrays are: •Two level arrays: L4, L8, L12, L16, L32 •Three level arrays: L9, L18, L27
  17. 17. TAGUCHI L9 ORTHOGONAL ARRAY DESIGN MATRIX IS SELECTED FROM ARRAY TABLEExp. Factor Factor Factor EXP PARAMETERS LEVELNo. 1 2 3 NO VOLT CUR PULSE 01 1 1 1 AGE RENT ON 02 1 2 2 TIME 03 1 3 3 1 6 2 35 04 2 1 2 2 6 3 40 05 2 2 3 3 6 4 45 4 7 2 40 06 2 3 1 5 7 3 45 07 3 1 3 6 7 4 35 08 3 2 1 7 5 2 45 8 5 3 35 09 3 3 2 9 5 4 40
  18. 18. SLECTION OF MATERIAL FOR EDM OF ALLOYSTEEL(SK-5) MATERIAL HAS BEEN CONSIDER USINGCOPPER ELECTRODE Dia Of Electrode : 9.4mm
  19. 19. EXPERIMENTRAL OBSERAVATION & CALCULATION OF VARIOUS RESPONSE FACTORS BASED ON TAGUCHI L9 ORTHOGONAL ARRAY PARAMETER LEVELS MACHI MACHI MRR 1 MRR2 EXP VOLTA CURRE PULSE NING NIG In In NO GE NT ON TIME 1 TIME 2 mm3/sec mm3/sec TIME In secs In secs 1 6 2 35 92 94 0.2008 0.1511 2 6 3 40 79 83 0.2426 0.1994 3 6 4 45 45 43 0.3281 0.3097 4 7 2 40 38 34 0.2962 0.3036 5 7 3 45 49 46 0.3321 0.3416 6 7 4 35 69 70 0.2097 0.1987 7 5 2 45 68 67 0.2434 0.2247 8 5 3 35 96 97 0.1352 0.1359 9 5 4 40 73 70 0.1864 0.1805
  20. 20. SIGNAL TO NOISE RATIO Taguchis emphasis on minimizing deviation from targetled him to develop measures of the process output thatincorporate both the location of the output as well as thevariation. These measures are called signal to noise ratios. The signal to noise ratio provides a measure of the impactof noise factors on performance.
  21. 21.  There are 3 Signal-to-Noise ratios of commoninterest for optimization of Static Problems SMALLER- NOMINAL- LARGER-THE-BETTER THE-BEST THE-BETTERNOMINAL-THE-BESTn = 10 Log10 [ square of mean/ variance ]This case arises when a specified value is MOST desired,meaning that neither a smaller nor a larger value is desirable
  22. 22. CALCULATION OF SIGNAL TO NOISE RATIO FOR MRR AND MT PARAMETER LEVELS SN SNEXP NO VOLTAGE CURRENT PULSE ON RATIO for RATIO for TIME MT MRR 1 6 2 35 36.3594 13.8276 2 6 3 40 29.1388 18.0704 3 6 4 45 29.8588 28.4448 4 7 2 40 22.0952 36.8242 5 7 3 45 27.0017 45.1361 6 7 4 35 39.8500 29.1000 7 5 2 45 39.5964 24.8895 8 5 3 35 42.7008 26.5849 9 5 4 40 30.5540 53.5758
  23. 23. Response Table for Signal to Noise Ratios for MT LEVEL VOLTAGE IN V CURRENT IN PULSE ON AMP TIME 1 37.6162 32.6788 39.6364 2 31.7912 32.9521 27.2640 3 29.6429 33.4194 32.1499 Δ 7.9733 0.7406 12.3724 RANK 2 3 1Therefore, PULSE ON TIME has the maximum effect on MACHININGTIME
  24. 24. Response Table for Signal to Noise Ratios for MRR LEVEL VOLTAGE IN CURRENT IN PULSE ON V AMP TIME 1 35.02 25.18 23.17 2 20.11 29.93 36.16 3 37.02 37.04 32.82 Δ 16.91 11.86 12.99 RANK 1 3 2Therefore VOLTAGE has the largest effect on MATERIALREMOVAL RATE.
  25. 25. SIMILARLY (WEDM) OF AL-6061 MATERIAL HASBEEN CONSIDER USING WEDM WITH A BRASS WIRE ELECTRODE
  26. 26. EXPERIMENTRAL AND SLECTION OF PROCESS PARAMETERS FOR CNC EDMInput Factors:- Responses measured:-Voltage (v)  Machining time (MT), Cutting speed (CS)Current (Ip)Voltage gap (Vg)Wire tension (WT) LEVEL VALUES OF INPUT FACTORS Symbols Testing parameters Level1 Level2 Level3 A Voltage (V) 6 8 10 B Current(I) 4 7 9 C Voltage gap (Vg) 55 58 60 D Wire tension (WT) 8 9 10
  27. 27. EXPERIMENTAL RESULTS AND CALCULATIONS OF VARIOUSRESPONSE FACTORS BASED ON TAGUCHI L9 ORTHOGONAL ARRAYCalculation of Signal to Noise ratio for MTEXP PARAMETER LEVELS MT1 MT2 SNNO In sec In sec RATIO VOLTAGE CURRENT VOLTAGE WIRE (V) (I) GAP (VG) TENSION (WT) 1 6 4 55 8 12.54 12.07 31.3683 2 6 7 58 9 8.02 7.58 27.9796 3 6 9 60 10 15.20 14.54 30.0635 4 8 4 58 10 12.36 12.10 36.4588 5 8 7 60 8 6.57 6.54 49.7993 6 8 9 55 9 2.52 2.40 29.2427 7 10 4 60 9 12.46 12.01 31.6966 8 10 7 55 10 3.31 3.17 30.2966 9 10 9 58 8 3.02 2.50 17.4697
  28. 28. CALCULATION OF SIGNAL TO NOISE RATIO FOR CSEXP PARAMETER LEVELS CS1 CS2 SN RATIONO VOLTAGE CURRENT VOLTAGE GAP WIRE TENSION In mm/sec In (V) (I) (VG) (WT) Mm/sec1 6 4 55 8 1.3 1.32 39.33482 6 7 58 9 1.7 1.89 22.50433 6 9 60 10 0.5 1.27 3.30824 8 4 58 10 1.1 1.40 15.34305 8 7 60 8 2.9 2.46 18.67456 8 9 55 9 5.6 6.18 23.13357 10 4 60 9 1.3 1.34 33.37958 10 7 55 10 4.6 4.89 27.28309 10 9 58 8 5.4 6.10 21.2855
  29. 29. RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS FOR MT LEVEL VOLTAGE IN CURRENT IN VOLTAGE WIRE V AMP GAP TENSION 1 29.8038 33.1745 30.3025 32.8791 2 38.5002 36.0251 27.3027 29.6396 3 26.4876 25.5919 37.1864 32.2729 Δ 12.0126 10.4332 9.8837 3.2395 RANK 1 2 3 4RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS FOR CS LEVEL VOLTAGE IN CURRENT VOLTAGE WIRE V IN AMP GAP TENSION 1 21.7157 29.3524 29.9171 26.4316 2 19.0503 22.8206 19.7109 26.3391 3 27.316 15.9090 18.4540 15.3114 Δ 8.2657 13.4434 11.4631 11.1202 RANK 4 1 2 3
  30. 30. CONCLUSION FOR CNC EDM  The MACHINING TIME (MT) mainly affected by PULSE ON TIME, VOLTAGE has less effect on it. Current (I) has a least effect on MT.  The MATERIAL REMOVAL RATE (MRR) is mainly influenced by VOLTAGE, The effect of PULSE ON TIME is less and Current has least effect on it.Exp no. 4 is the OPTIMIZED PARAMETER for MTExp no. 1 is the OPTIMIZED PARAMETER for MRR
  31. 31. CONCLUSION FOR CNC WEDMThe MACHINING TIME (MT) mainly affected byVOLTAGE , CURRENT &VOLTAGE GAP has lesseffect on it. WIRE TENSION has a least effect on MTThe CUTTING SPEED (CS) is mainly influenced byCURRENT, The effect of VOLTAGE GAP ,WIRETENSION is less and VOLTAGE has least effect on it.Exp no. 9 is the OPTIMIZED PARAMETER for MTExp no. 3 is the OPTIMIZED PARAMETER for CS
  32. 32. REFERENCES Abbas, N.M., Solomon, D.G., Bahari, M. F. (2007), “A review on current research trends in electrical discharge machining (EDM)”, International Journal of Machine Tools & Manufacture, 47, 1214–1228. Adler, Yu. P., Markova, E.V., Granovsky, Yu.V. (1975),“The design of experiments to find optimal conditions”, Mir Publishers, Moscow. Pandey P C , Shan H S, Modern Machining Processes, Tata McGraw-Hill publishing Company Limited, New Delhi, (1999). Phadke M.S, Quality Engineering Using Robust Design, Prentice- Hall, Englewood Cliffs,NJ, (1989).
  33. 33. QUERIES

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