the implimentation of taguchi method on cnc edm and wedm process
TRANSCRIPT
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By
KIRAN H G
RAGHUNANDAN H S
RAJESH S
VINITESH K V
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S
T
R
C
T
KEYWORDS: CNC EDM, CNC
WEDM, Taguchi method, DOE,
Orthogonal array
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C
O
N
T
E
N
T
INTRODUCTION
DESIGNOFEXPERIMENT
TAGUCHI METHOD
EXPERIMENTRAL AND SLECTIONOF PROCESS PARAMETERS
EXPERIMENTRAL OBSERAVATION
EXPERIMENTRAL RESULTS ANDANALYSIS TAGUCHI METHOD
CONCLSIONS
REFERENCES
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EDM is mainly used to machine difficult-to-
machine materials.
The electrode is made from electrically conductivematerial.
Dielectric fluid should be nonconductor of electricity
EDNC 32H MAKINO high precision CNC EDM
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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 CNCWEDM
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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.
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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
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DR. GENICH I TAGUCHI
Dr. GenichiTaguchi wasBorn in Japan,1924. He is an
ElectricalEngineer andWorked during1950s toimprove Japans
post-WWIItelephonecommunicationsystem And alsocalled Father ofthe
TaguchiMethod andRobustEngineering
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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
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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
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INITIATING STEPS
1. PROBLEMIDENTIFICATION
2. BRAINSTORMINGSESSION
(Identify:- Factors,Factors settings ,
Possible Interaction, Objectives)
3.EXPERIMENTAL
DESIGN
(Choose orthogonalarrays, Design
Experiment )
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4. RUN EXPERIMENT
5. ANALYZE RESULTS
6.CONFIRMATION RUNS
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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
https://controls.engin.umich.edu/wiki/index.php/File:Selector.jpghttps://controls.engin.umich.edu/wiki/index.php/File:Selector.jpg -
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Orthogonal Arraysrepresent 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
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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
VOL
TAG
E
CUR
RENT
PULSE
ON
TIME
1 6 2 35
2 6 3 40
3 6 4 45
4 7 2 40
5 7 3 45
6 7 4 35
7 5 2 45
8 5 3 359 5 4 40
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SLECTION OF MATERIAL FOR EDM OF ALLOY
STEEL (SK-5) MATERIAL HAS BEEN CONSIDER USING
COPPER ELECTRODE
Dia OfElectrode:
9.4mm
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EXPERIMENTRAL OBSERAVATION & CALCULATION
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EXPERIMENTRAL OBSERAVATION & CALCULATIONOF VARIOUS RESPONSE FACTORS BASED ON
TAGUCHI L9 ORTHOGONAL ARRAY
EXP
NO
PARAMETER
LEVELS
MACHI
NING
TIME 1
In secs
MACHI
NIG
TIME 2
In secs
MRR 1
In
mm3/sec
MRR2
In
mm3/secVOLTA
GE
CURR
ENT
PULSE
ON
TIME
1 6 2 35 92 94 0.2008 0.151
1
2 6 3 40 79 83 0.2426 0.199
4
3 6 4 45 45 43 0.3281 0.309
7
4 7 2 40 38 34 0.2962 0.303
6
5 7 3 45 49 46 0.3321 0.341
6
6 7 4 35 69 70 0.2097 0.198
7
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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
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CALCULATION OF SIGNAL TO NOISE RATIO FOR
MRR AND MT
EXP NO
PARAMETER LEVELS SN
RATIO forMT
SN
RATIO forMRR
VOLTAGE CURRENT
PULSEON TIME
1 6 2 35 36.3594
13.8276
2 6 3 40 29.1388
18.0704
3 6 4 45 29.858
8
28.4448
4 7 2 40 22.0952 36.8242
5 7 3 45 27.001
7
45.1361
6 7 4 35 39.850
0
29.1000
7 5 2 45 39.596 24.8895
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Response Table for Signal to Noise Ratios for MT
LEVEL VOLTAGE INV
CURRENT INAMP
PULSE ONTIME
1 37.6162 32.6788 39.6364
2 31.7912 32.9521 27.2640
3 29.6429 33.4194 32.1499
7.9733 0.7406 12.3724
RANK 2 3 1
Therefore, PULSE ON TIME has the maximum effect on MACHINING
TIME
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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
16.91 11.86 12.99
RANK 1 3 2
Therefore VOLTAGEhas the largest effect on MATERIAL
REMOVAL RATE.
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SIMILARLY (WEDM) OF AL-6061 MATERIAL HAS
BEEN CONSIDER USING WEDM WITH A BRASS WIRE
ELECTRODE
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Input Factors:-
Voltage (v)
Current (Ip)
Voltage gap (Vg)
Wire tension (WT)
EXPERIMENTRAL AND SLECTION OF PROCESSPARAMETERS FOR CNC EDM
Responses measured:-
Machining time (MT),
Cutting speed (CS)
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
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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
RATIOVOLTAG
E (V)
CURRENT
(I)
VOLTAGE
GAP (VG)
WIRE
TENSION
(WT)
1 6 4 55 8 12.54 12.07 31.368
3
2 6 7 58 9 8.02 7.58 27.979
6
3 6 9 60 10 15.20 14.54 30.063
54 8 4 58 10 12.36 12.10 36.458
8
5 8 7 60 8 6.57 6.54 49.799
3
6 8 9 55 9 2.52 2.40 29.242
77 10 4 60 9 12.46 12.01 31.696
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CALCULATION OF SIGNAL TO NOISE RATIO FOR CS
EX
P
NO
PARAMETER LEVELS CS1
In
mm/sec
CS2
In
Mm/sec
SN RATIO
VOLTAG
E (V)
CURREN
T
(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
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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
32.8791
2
38.5002
36.0251
27.3027
29.6396
3
26.4876
25.5919
37.1864
32.2729
12.0126 10.4332 9.8837 3.2395
RANK
1
2
3
4
RESPONSE 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
8.2657 13.4434 11.4631 11.1202
RANK
4
1
2
3
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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
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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
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QUERIES