implimentation of taguchi method on cnc edm and cnc wedm
TRANSCRIPT
THE IMPLIMENTATION OF TAGUCHI METHOD ON CNC EDM AND WEDM
PROCESS
By,
KIRAN H G
RAGHUNANDAN H S
RAJESH S
VINITESH K V
PROJECT SEMINARON
VISVESVARAYA TECHNOLOGICAL UNIVERSITYBELGAUM-590018
UNDER THE GUIDANCE OF
RAMESH BABU K
PRINCIPAL-PG STUDIESGT&TC ,MYSORE
LINGARAJU K N
ASST. PROFESSOR
DEPT OF MECHANICAL ENGINEERING
GEC,CHAMARAJANAGARA
ABSTRACT
KEYWORDS: CNC EDM, CNC WEDM, Taguchi method, DOE,
Orthogonal array
CONTENT
INTRODUCTION
DESIGN OF EXPERIMENT
TAGUCHI METHOD
EXPERIMENTRAL AND SLECTION OF PROCESS PARAMETERS
EXPERIMENTRAL OBSERAVATION
EXPERIMENTRAL RESULTS AND ANALYSIS TAGUCHI METHOD
CONCLSIONS
REFERENCES
INTRODUCTION
EDM is an electro-thermal non-traditional machining process, where electrical energy is used to generate electrical spark and material removal mainly occurs due to thermal energy of the spark
The work material is removed by a series of sparks that cause localized melting and evaporation of the material
EDNC 32H MAKINO high precision CNC EDM
EDM is mainly used to machine difficult-to-machine materials.
The electrode is made from electrically conductive material.
Dielectric fluid should be nonconductor of electricity
EDNC 32H MAKINO high precision CNC EDM
WIRE CUT ELECTRO DISCHARGE MACHINING (WEDM),
WEDM is electro-thermal mechanisms to cut electrically conductive material.
WEDM has become the essential part of many manufacturing process industries, which need variety, precision and accuracy
FA10S MITSUBISHI high precision CNC WEDM
DESIGN OF EXPERIMENT
Design of Experiments (DOE) refers to planning,
designing and analyzing an experiment so that valid and
objective conclusions can be drawn effectively and efficiently.
The input variables are called Factors and the output
variables are called Response.
THE ADVANTAGES OF DESIGN OF EXPERIMENTS ARE
Numbers of trials is significantly reduced.
Optimal setting of the parameters can be found
out.
Qualitative estimation of parameters can be
made.
Experimental error can be estimated.
Inference regarding the effect of parameters on
the characteristics of the process
DR. GENICHI TAGUCHI
Dr. Genichi Taguchi was 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
HE SUGGESTED THAT THE DESIGN PROCESS SHOULD BE SEEN AS THREE STAGES
1• SYSTEM
DESIGN
2• PARAMETER
DESIGN
3• TOLERANCE
DESIGN
In this present work, the Taguchi method has been used to plan the experiments for parameter design and subsequent analysis of the data collected
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
INITIATING STEPS
1. PROBLEM IDENTIFICATION
2. BRAIN STORMING SESSION (Identify:-
Factors ,Factors settings , Possible Interaction ,
Objectives)
3. EXPERIMENTAL DESIGN
(Choose orthogonal arrays, Design Experiment )
4. RUN EXPERIMENT
5. ANALYZE RESULTS
6.CONFIRMATION RUNS
EXPERIMENTRAL AND SLECTION OF PROCESS PARAMETERS FOR CNC EDM
INPUT FACTORS FOR CNC EDM
1) VOLTAGE (V)2) CURRENT (I)3) PULSE ON TIME (TON)
RESPONSES MEASURED FOR EDM
1) MATERIAL REMOVAL RATE (MRR),2) MACHINING TIME
Array Selector
TABLE 1:- LEVEL VALUES OF INPUT FACTOR
Symbols 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
Orthogonal Arrays represent a versatile class of
combinational arrangements useful for conducting
experiments.
ORTHOGONAL ARRAYS
The standard two level and three level arrays are:
•Two level arrays: L4, L8, L12, L16, L32
•Three level arrays: L9, L18, L27
TAGUCHI L9 ORTHOGONAL ARRAY DESIGN MATRIX IS SELECTED FROM ARRAY TABLE
Exp.
No.
Factor
1
Factor
2
Factor
3
01 1 1 1
02 1 2 2
03 1 3 3
04 2 1 2
05 2 2 3
06 2 3 1
07 3 1 3
08 3 2 1
09 3 3 2
EXP NO
PARAMETERS LEVEL
VOLTAGE
CURRENT
PULSE ON
TIME
1 6 2 352 6 3 403 6 4 454 7 2 405 7 3 456 7 4 357 5 2 458 5 3 359 5 4 40
SLECTION OF MATERIAL FOR EDM OF ALLOY STEEL(SK-5) MATERIAL HAS BEEN CONSIDER USING COPPER ELECTRODE
Dia Of Electrode : 9.4mm
EXPERIMENTRAL OBSERAVATION & CALCULATION OF VARIOUS RESPONSE FACTORS BASED ON
TAGUCHI L9 ORTHOGONAL ARRAY
EXP NO
PARAMETER LEVELS
MACHINING TIME
1In
secs
MACHINIG TIME
2In
secs
MRR 1In
mm3/sec
MRR2 In mm3/sec
VOLTAGE
CURRENT
PULSE ON
TIME
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
Taguchi's emphasis on minimizing deviation from target
led him to develop measures of the process output that
incorporate both the location of the output as well as the
variation. These measures are called signal to noise ratios.
The signal to noise ratio provides a measure of the
impact of noise factors on performance.
SIGNAL TO NOISE RATIO
There are 3 Signal-to-Noise ratios of common
interest for optimization of Static Problems
SMALLER-THE-BETTER
NOMINAL-THE-BEST
LARGER-THE-BETTER
n = 10 Log10 [ square of mean/ variance ]
NOMINAL-THE-BEST
This case arises when a specified value is MOST desired, meaning that neither a smaller nor a larger value is desirable
CALCULATION OF SIGNAL TO NOISE RATIO FOR MRR AND MT
EXP NOPARAMETER LEVELS SN
RATIO for MT
SN RATIO
for MRRVOLTAGE CURREN
TPULSE
ON TIME
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
Response Table for Signal to Noise Ratios for MT
LEVEL VOLTAGE IN
V
CURRENT IN
AMP
PULSE ON
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 1
Therefore, PULSE ON TIME has the maximum effect on MACHINING TIME
Response Table for Signal to Noise Ratios for MRR
LEVEL VOLTAGE IN
V
CURRENT IN
AMP
PULSE ON
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 2
Therefore VOLTAGE has the largest effect on MATERIAL REMOVAL RATE.
SIMILARLY (WEDM) OF AL-6061 MATERIAL HAS BEEN CONSIDER USING WEDM WITH A BRASS WIRE
ELECTRODE
Input Factors:-
Voltage (v)
Current (Ip)
Voltage gap (Vg)
Wire tension (WT)
EXPERIMENTRAL AND SLECTION OF PROCESS PARAMETERS FOR CNC EDM
Responses measured:- Machining time (MT),Cutting speed (CS)
LEVEL VALUES OF INPUT FACTORS
SymbolsTesting
parametersLevel1 Level2 Level3
A Voltage (V) 6 8 10
B Current(I) 4 7 9
CVoltage gap
(Vg)55 58 60
DWire tension
(WT)8 9 10
EXPERIMENTAL RESULTS AND CALCULATIONS OF VARIOUS RESPONSE FACTORS BASED ON TAGUCHI L9 ORTHOGONAL
ARRAY
Calculation of Signal to Noise ratio for MT
EXP NO
PARAMETER LEVELS MT1 In sec
MT2 In sec
SN RATIO
VOLTAGE (V)
CURRENT(I)
VOLTAGE GAP (VG)
WIRE 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
CALCULATION OF SIGNAL TO NOISE RATIO FOR CS
EXP
NO
PARAMETER LEVELS CS1In
mm/sec
CS2In
Mm/sec
SN RATIOVOLTAG
E (V)CURRENT
(I)VOLTAGE
GAP (VG)
WIRE TENSION
(WT)
1 6 4 55 8 1.3 1.32 39.3348
2 6 7 58 9 1.7 1.89 22.5043
3 6 9 60 10 0.5 1.27 3.3082
4 8 4 58 10 1.1 1.40 15.3430
5 8 7 60 8 2.9 2.46 18.6745
6 8 9 55 9 5.6 6.18 23.1335
7 10 4 60 9 1.3 1.34 33.3795
8 10 7 55 10 4.6 4.89 27.2830
9 10 9 58 8 5.4 6.10 21.2855
RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS FOR MT
LEVEL VOLTAGE IN V
CURRENT IN AMP
VOLTAGE GAP
WIRE TENSION
1 29.8038 33.1745 30.3025 32.87912 38.5002 36.0251 27.3027 29.63963 26.4876 25.5919 37.1864 32.2729Δ 12.0126 10.4332 9.8837 3.2395
RANK 1 2 3 4RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS FOR CS
LEVEL VOLTAGE IN V
CURRENT IN AMP
VOLTAGE GAP
WIRE 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
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 MT
Exp no. 1 is the OPTIMIZED PARAMETER for MRR
CONCLUSION FOR CNC WEDM
The MACHINING TIME (MT) mainly affected by
VOLTAGE , CURRENT &VOLTAGE GAP has less
effect on it. WIRE TENSION has a least effect on MT
The CUTTING SPEED (CS) is mainly influenced by
CURRENT, The effect of VOLTAGE GAP ,WIRE
TENSION is less and VOLTAGE has least effect on it.
Exp no. 9 is the OPTIMIZED PARAMETER for MT
Exp no. 3 is the OPTIMIZED PARAMETER for CS
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).
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