The Implimentation of Taguchi Method on Cnc Edm and Wedm Process

8/10/2019 The Implimentation of Taguchi Method on Cnc Edm and Wedm Process

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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

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T

E

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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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The Implimentation of Taguchi Method on Cnc Edm and Wedm Process

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