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Taguchi Method Assignment

The document discusses the Taguchi method for optimizing process parameters to improve quality. It involves identifying control factors that can minimize the effects of noise factors. Orthogonal arrays are used to conduct experiments with fewer runs than a full factorial design. A case study on facing operations illustrates the Taguchi method steps: identifying control/noise factors affecting surface finish, selecting factor levels, choosing an orthogonal array, conducting the experiment, and finding the optimal factor levels. A full factorial design would require more experiments compared to the Taguchi method.

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123 views6 pages

Taguchi Method Assignment

The document discusses the Taguchi method for optimizing process parameters to improve quality. It involves identifying control factors that can minimize the effects of noise factors. Orthogonal arrays are used to conduct experiments with fewer runs than a full factorial design. A case study on facing operations illustrates the Taguchi method steps: identifying control/noise factors affecting surface finish, selecting factor levels, choosing an orthogonal array, conducting the experiment, and finding the optimal factor levels. A full factorial design would require more experiments compared to the Taguchi method.

Uploaded by

puri
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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ASSIGNMENT NO.

TAGUCHI METHOD

NAME:- HANUMANT DESHMUKH


ROLL NO. :- 2017MTEMEPR011
Taguchi Method
Taguchi Method is a statistical approach to optimize the process parameters
and improve the quality of components that are manufactured. Success in
achieving the desired results involves a careful selection of process parameters and
differentiates them into control and noise factors. Selection of control factors must
be made such that it nullifies the effect of noise factors. Taguchi Method involves
identification of proper control factors to obtain the optimum results of the process.
Orthogonal Arrays (OA) are used to conduct a set of experiments. Results of these
experiments are used to analyze the data and predict the quality of components
produced.

Full Factorial Design


A full factorial experiment is an experiment whose design consists of two or
more factors, each with a discrete possible level and whose experimental units take
all possible combinations of all those levels across all such factors. Such an
experiment allows studying the effect of each factor on the response variable, as
well as on the effects of interactions between factors on the response variable. A
common experimental design is the one with all input factors set at two levels
each. If there are k factors each at 2 levels; a full factorial design has 2k runs. Thus
fo0r 6 factors at two levels it would take 64 trial runs.

Taguchi Method
The Full Factorial Design requires a large number of experiments to be
carried out as stated above. It becomes laborious and complex, if the number of
factors increase. To overcome this problem Taguchi suggested a specially designed
method called the use of orthogonal array to study the entire parameter space with
lesser number of experiments to be conducted. Taguchi thus, recommends the use
of the loss function to measure the performance characteristics that are deviating
from the desired target value. The value of this loss function is further transformed
into signal-to-noise (S/N) ratio. Usually, there are three categories of the
performance characteristics to analyze the S/N ratio. They are: nominal-the-best,
larger-the-better, and smaller-the-better.
Steps Involved in Taguchi Method
The use of Taguchis parameter design involves the following steps.
a. Identify the main function and its side effects.
b. Identify the noise factors, testing condition and quality characteristics.
c. Identify the objective function to be optimized.
d. Identify the control factors and their levels.
e. Select a suitable Orthogonal Array and construct the Matrix
f. Conduct the Matrix experiment.
g. Examine the data; predict the optimum control factor levels and its performance.
h. Conduct the verification experiment.

Case study on facing operation


Approach to the Experimental Design
In accordance with the steps that are involved in Taguchis Method, a series of
experiments are to be conducted. Here, facing operation on mild steel components
using a lathe has been carried out as a case study. The procedure is given below.

Identification of Main Function and its side effects


Main function: Facing Operation on MS work piece using lathe machine. Side
effects : Variation in surface finish. Before proceeding on to further steps, it is
necessary to list down all the factors that are going to affect or influence the facing
process and from those factors one has to identify the control and noise factors.
The Factors that affect facing operation on a lathe machine are listed in the table

Factors that affect facing operation


Control factors Noise Factors
Cutting speed Vibration
Depth of cut Raw material variation
Feed rate Machine Condition
Nose radius Temperature
Coolant Operator Skill

After listing the control and the noise factors, decisions on the factors that
significantly affect the performance will have to be ascertained and only those
factors must be taken in to consideration in constructing the matrix for
experimentation. All other factors are considered as Noise Factors

Identifying the Testing Conditions and Quality Characteristics to Be


Observed
Quality Characteristic: Surface finish Work piece material: Mild Steel Application
of Taguchi Method for Optimization of Process Parameters in Improving the
Surface www.irjes.com 15 | Page
Cutting tool: Tungsten: Carbide Tipped tool Operating Machine: Lathe machine
Testing Equipment: Portable surface tester

Identifying the Control Factors and their levels


The factors and their levels were decided for conducting the experiment, based on
a brain storming session that was held with a group of people and also
considering the guide lines given in the operators manual provided by the
manufacturer of the lathe machine. The factors and their levels are shown in table

FACTORS Levels
1 2 3
Cutting speed(v, 960 640 1280
rpm)

Depth of cut(t, mm) .3 .2 .4


Feed rate(f, 145 130 160
mm/min)

Selection of Orthogonal Array


To select an appropriate orthogonal array for conducting the experiments, the
degrees of freedom are to be computed. The same is given below: Degrees of
Freedom: 1 for Mean Value, and 8= (2x4), two each for the remaining factors
Total Degrees of Freedom: 9 The most suitable orthogonal array for
experimentation is L9 array a Therefore, a total nine experiments are to be carried
out.

Experimental Details
Since the objective function (Surface Finish) is smaller-the-better type of control
function, was used in calculating the S/N ratio. The S/N ratios of all the
experiments were calculated and tabulated as shown in Table

Experiment No. S/N Ratio (dB)


1 -7.9702
2 -9.2568
3 -10.4539
4 -10.9196
5 -11.0971
6 -12.1010
7 -9.2385
8 -10.4642
9 -9.2941

Optimum values of factors and their levels

Parameter Optimum Value


Speed (rpm) 960
Feed Rate (mm/min) 145
Depth of cut (mm) 0.3
Full Factorial Analysis A full factorial analysis consists of conducting
experiments taking into account all the possible combinations of the factors and
their levels. As far as the following experiments are concerned the 3 factors i.e.;
speed, feed, and depth of cut were considered at 3 different levels. These were
compared with the results of the fractional factorial that was conducted using
Taguchi method. It will take 27 experiments. Thislead to more time.

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