Journal of Manufacturing Technology Management

Emerald Article: Optimizing multi-machining characteristics through Taguchi's approach and utility concept Hari Singh, Pradeep Kumar

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To cite this document: Hari Singh, Pradeep Kumar, (2006),"Optimizing multi-machining characteristics through Taguchi's approach and utility concept", Journal of Manufacturing Technology Management, Vol. 17 Iss: 2 pp. 255 - 274 Permanent link to this document: http://dx.doi.org/10.1108/17410380610642304 Downloaded on: 28-07-2012 References: This document contains references to 25 other documents To copy this document: permissions@emeraldinsight.com This document has been downloaded 1557 times since 2006. *

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Optimizing multi-machining characteristics through Taguchis approach and utility concept

Hari Singh
Mechanical Engineering Department, National Institute of Technology, Kurukshetra, India, and

Optimizing multi-machining characteristics 255

Received August 2004 Revised March 2005 Accepted May 2005

Pradeep Kumar
Department of Mechanical and Industrial engineering, Indian Institute of Technology, Roorkee, India
Abstract
Purpose Taguchis technique is best suited to optimize a single performance characteristic yielding an optimal setting of process parameters. A single setting of process parameters may be optimal for one quality characteristics but the same setting may yield detrimental results for other quality features. Thus the purpose of this paper is to describe simultaneous optimization of multi-characteristics. Design/methodology/approach The multi-machining characteristics have been optimized simultaneously using Taguchis parameter design approach and the utility concept. The paper used a single performance index, utility value, as a combined response indicator of several responses. Findings A simplied model based on Taguchis approach and utility concept is used to determine the optimal settings of the process parameters for a multi-characteristic product. The model is used to predict optimal settings of turning process parameters to yield the optimum quality characteristics of En24 steel turned parts using TiC coated carbide inserts. The optimal values obtained using the multi-characteristic optimization model have been validated by conrmation experiments. The model can be extended to any number of quality characteristics provided proper utility scales for the characteristics are available from the realistic data. Practical implications The proposed methodology can be applied to those industrial situations where a number of responses are to be optimized simultaneously. Originality/value The paper discusses a case study on En24 steel turned parts using titanium carbide coated tungsten carbide inserts. The material, En24 steel, has wide applications in aerospace, machine tools, automobiles, etc. The proposed algorithm is easy to apply. Keywords Taguchi methods, Utility theory, Production processes Paper type Case study

Introduction The Taguchis approach for determining the optimal settings of controllable parameters through ofine experiments focuses on products with a single quality characteristic. But most of the products have several quality features of interest. A single setting of process parameters may be optimal for one response but the same setting may yield detrimental results for other responses. In such cases, a need arises to obtain an optimal setting of the process parameters so that the product can be produced with optimum or near optimum responses. This problem has been investigated by researchers who developed approaches for products with multiple characteristics.

Journal of Manufacturing Technology Management Vol. 17 No. 2, 2006 pp. 255-274 q Emerald Group Publishing Limited 1741-038X DOI 10.1108/17410380610642304

JMTM 17,2

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Literature review on multi-response optimization A number of techniques have been developed by the researchers for optimizing multiple characteristics of the products. Taraman (1974) investigates multi machining output multi independent variable turning research by response surface methodology. The purpose of this research was to develop a methodology which would allow determination of the cutting conditions (cutting speed, feed rate and depth of cut) such that specied criterion for each of the several machining dependent parameters (surface nish, tool force and tool life TL) could be achieved simultaneously. A central composite design was used to develop mathematical models correlating the dependent and independent parameters of the process. Disposable inserts of tungsten carbide were used to turn SAE1018 cold rolled steel. Byrne and Taguchi (1987) illustrate a case of the optimization of two quality characteristics: the force required to insert the tube into the connector and the pull off force. The selected quality characteristics were independently optimized using Taguchi approach and then the results were compared subjectively to select the best levels in terms of the quality characteristics of interest. Phadke (1989) presents a case of products with multiple characteristics such as surface defects and thickness in his example of polysilicon deposition. In order to estimate the loss caused by quality characteristics, he assigned a weight from experience to each quality characteristic. Elsayed and Chen (1993) present a model using loss function approach to determine the optimal settings of the process parameters of the production process for products with multiple characteristics. Tong et al. (1997) propose a procedure on the basis of the quality loss of each response so as to achieve the optimization on multi-response problems in the Taguchi method. The procedure is a universal approach which can simultaneously deal with continuous and discrete data. A plasma-enhanced chemical vapor deposition process experiment was evaluated to prove that the proposed procedure yields a satisfactory result. Su and Tong (1997) propose an effective procedure on the basis of principal component analysis (PCA) to optimize the multi-response problems in the Taguchi method. With the PCA, a set of original responses can be transformed into a set of uncorrelated components. Therefore, the conict for determining the optimal settings of the design parameters for the multi-response problems can be reduced. Reddy et al. (1997) present an approach to optimize multi responses simultaneously using goal programming in conjunction with Taguchis robust design methodology. A case study for optimizing an injection moulding process is rst carried out using Taguchi robust design methodology. The optimization study revealed that the optimum conditions obtained for one response are not completely compatible with those of other responses. So trade offs were made in selection of levels for factors using engineering judgment which increased the uncertainty in the decision-making process. The further optimization study on the injection moulding process revealed that the optimum conditions obtained using goal programming in conjunction with Taguchis methodology have better goal attainment properties compared to robust design. Antony (2000) presents a case study for optimizing multi-responses in industrial experiments using Taguchis quality loss function in conjunction with PCA. The approach is able to eliminate the uncertainty and subjectivity in the decision-making process. Tarang et al. (2000) report the use of fuzzy logic in the Taguchi method to optimize the submerged arc welding process with multiple performance characteristics. An orthogonal array (OA), the signal-to-noise ratio, multi response

performance index and analysis of variance (ANOVA) are employed to study the performance characteristics in the submerged arc welding process. The process parameters, namely arc current, arc voltage, welding speed, electrode protrusion, and preheat temperature are optimized with considerations of the performance characteristics, including deposition rate and dilution. Experimental results conrm the effectiveness of the approach. Antony (2001) has developed a simple and practical step-by-step approach for tackling multiple response or quality characteristic problems in Taguchis parameter design experiments. The methodology uses the Taguchis quality loss function for identifying the signicant factor/interaction effects and also for determining the optimal condition of the process. In order to demonstrate the potential of the proposed methodology, a simple case study was carried out for optimizing three quality characteristics, namely solder paste mass, solder paste height, and glue torque, for a double-sided surface mounting technology electronic assembly operation. Six controllable factors and one interaction effect were studied using an L8 OA experiment advocated by Taguchi. Lu and Antony (2002) present a robust and practical approach which takes advantage of both the Taguchi method and a fuzzy-rule based inference system. A case study illustrates the potential of this powerful integrated approach for tackling multiple response optimization problems. The variance analysis used in the study identies the most critical and statistically signicant parameters. Liao (2003) proposes an effective procedure called PCR-TOPSIS that is based on process capability ratio theory and on the theory of order preference by similarity to the ideal solution (TOPSIS) to optimize multi-response problems. Using PCR-TOPSIS, multiple responses in each experiment are transformed into a performance index and the optimal factors/levels combinations for the multi-responses can thus be determined. The results of two case studies indicate that the approach can yield a satisfactory solution for multi-response problems. In this paper, a simplied methodology based on Taguchis approach and utility concept has been developed for determining optimal settings of the process parameters for multi-characteristic product. The trade off between conicting quality characteristics is made objective in the developed model through utility concept. A case study on En24 steel turned parts, utilizing a simplied multi-characteristic optimization model based on Taguchis technique and utility concept, is also discussed. Process parameters of turning operation In order to identify the process parameters that affect the quality of the turned parts, an Ishikawa cause-effect diagram was constructed as shown in Figure 1. The Ishikawa cause-effect diagram depicts that the following process parameters may affect the quality of the turned parts: . Cutting parameters: cutting speed, feed rate, depth of cut. . Environment parameters: wet, dry. . Cutting tool parameters: tool geometry, tool material. . Work piece material: hot worked, cold worked, difcult to machine. The following process parameters were identied as potentially important in affecting the quality features of the turned parts under study (Singh, 2000; Singh et al., 2001; Singh and Kumar, 2000, 2003a, b, c, 2004):

Optimizing multi-machining characteristics 257

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258

Figure 1. Ishikawa cause-effect diagram of a turning process

. . . . . .

cutting speed; feed rate; depth of cut; tool material WIDADUR TG inserts; work material En24 steel; and environment dry.

En24 steel is a difcult-to-machine material and nds its typical applications in the manufacturing of automobile and machine tool parts (Mottram and WoolMan, 1966). Because of its wide application En24 steel has been selected as the work material in this case study. The recently developed tool materials like coated carbides have improved the productivity levels of difcult-to-machine materials. Thus coated carbide tool Widadur TG of Widia India Limited has been selected to turn En24 steel. The ranges of the selected process parameters were decided by conducting the experiments and using one variable at a time approach (Singh, 2000; Singh and Kumar, 2000). The process parameters, their designated symbols and ranges are given in Table I. Each parameter was studied at three levels. Quality characteristics of turned parts Metal cutting processes consist of independent or input variables, dependent variables, and independent-dependent interactions. The independent variables are broadly grouped into the cutting tool parameters, the work piece parameters and the cutting parameters (Figure 1). One can select the independent parameters while setting up the cutting process. The dependent variables are determined by the process, based on the

prior selection of independent parameters. The important dependent parameters for turning process are cutting force (CF), power consumption (PC), dimensional accuracy, surface nish, tool wear and TL. The following features were selected to evaluate the quality of En24 steel turned parts: . surface roughness (SR); . tool life; . cutting force; and . power consumption. SR, CF and PC are lower the better type of responses whereas TL is higher the better type of quality characteristic. In the present case study, a simplied methodology based on Taguchis approach and utility concept has been used for determining optimal settings of the process parameters for multi-characteristic product. In fact, the methodology is an extension of Byrne and Taguchi (1987). The utility concept A customer evaluates a product based on a number of different quality characteristics. The evaluations of different characteristics should then be combined to give a composite index. Such a composite index represents the utility of the product. The utility of a product on a particular characteristic measures the usefulness of that particular characteristic of the product. In this paper it is assumed that the overall utility of a product is the sum of utilities of each of the quality characteristics. Thus if Xi is the measure of effectiveness of an attribute (characteristic) i and there are n attributes evaluating the outcome space, then the joint utility function can be expressed as (Derek, 1982): U X 1 ; X 2 ; . . . ; X n f U 1 X 1 ; U 2 X 2 ; . . . ; U n X n 1

Optimizing multi-machining characteristics 259

where Ui(Xi) is the utility of the ith attribute. Assuming that the attributes are independent and have no interactions between themselves, and the overall utility function is a linear sum of individual utilities, the function becomes: U X 1 ; X 2 ; . . . ; X n
n X i1

U i X i

The attributes may be given priorities as per customers requirements and corresponding weights for the individual utility index. The overall utility function can then be written as

Process parameters Cutting speed (m/min) Feed (mm/rev) Depth of cut (mm)

Designation A B C

L1 190 0.14 0.70

Levels L2 250 0.16 0.85

L3 310 0.18 1.00 Table I. Process parameters and their levels

JMTM 17,2

U X 1 ; X 2 ; . . . ; X n

n X i1

W i U i X i

260

Where Wi is the weight assigned to the attribute i and the sum of the weights for all attributes is equal to 1. The utility function is of higher the better type. If the composite measure (the overall utility) is maximized, the quality characteristics considered for the evaluation of utility will be optimized (maximized or minimized). Determination of utility value To determine the utility value for a number of quality characteristics, a preference scale for each quality characteristic is constructed. Later these scales are weighted to obtain a composite number (overall utility). The weighting is done to satisfy the test of indifference on the various quality characteristics. The preference scale should be a logarithmic one (Gupta and Murthy, 1980). The minimum acceptable quality level for each quality characteristic is set at a preference number of 0 and the best available quality is assigned a preference number of 9. If a log scale is chosen, the preference number (Pi) is given by Gupta and Murthy (1980): P i A log Xi X 0i 4

where Xi is the value of quality characteristic or attribute i, Xi0 is the minimum acceptable value of the quality characteristic or attribute i and A is a constant. Arbitrarily, we may choose A such that Pi 9 at Xi X *, where X * is the optimum value of Xi assuming such a number exists. So; A 9 log X * X0
i

The next step is to assign weights or relative importance to the quality characteristics. This assignment is subjective and based on experience. Moreover, it depends on the end use of the product or customers requirements. The weights should be assigned such that the following condition holds:
n X i1

Wi 1

The overall utility can be calculated as: U

n X i1

W iPi

The multi-characteristic optimization algorithm In this paper, the following algorithm is suggested based on Taguchis technique and utility concept.

. .

Find optimal values of the selected quality characteristics separately using Taguchi experimental design and analysis. Using the optimal values and the minimum quality levels for the characteristics from the experimental data, construct preference scale for each quality characteristic. Use equations (4) and (5). Assign weights Wi, i 1,2, . . . , n based on experience and end use of the product such that equation (6) is satised. Find utility values for each product against each trial condition of the experiment using equation (7). Use these values as a response of the trial conditions of the selected experimental plan. Analyze results using the procedure suggested by Taguchi (Roy, 1990). Find the optimal settings of the process parameters for optimum utility (mean and minimum deviation around the mean) based on the analysis in step 6. Predict the individual characteristic values considering the optimal signicant parameters determined in step 7. Conduct conrmation experiment at the optimal setting and compare the predicted optimal values of the quality characteristics with the actual ones.

Optimizing multi-machining characteristics 261

The ow chart of the methodology is shown in Figure 2. Optimization of an individual quality characteristic Taguchis technique is applied to identify the optimum levels of turning process parameters for each of the selected machining characteristics individually. The selection of an appropriate OA is a critical step in Taguchis experimental design. The OA selected should satisfy the following inequality (Ross, 1996): Degree of freedom (DOF) of OA $ Total DOF required for the experiments. Along with the three parameters (A, B and C), three interactions (A B, B C, A C) were also selected (Singh, 2000; Singh and Kumar, 2000). With the three parameters each at three-levels and three two factor interactions, the total DOF required was 18 ((3 2) (3 4)), the DOF of a three-level factor is 2 (number of levels-1) and that of two factor interaction is 4 (product of DOF of interacting factors). Thus L27 (313) OA was selected for the experiments. The L27 OA is a three-level OA having 27 trial conditions and can accommodate 13 parameters. Using a linear graph and a triangular table (Ross, 1996), the selected process parameters and interactions were assigned to the columns of the OA. The linear graph with main and interaction effects of interest is shown in Figure 3. The entire experimentation has been carried out in a phase manner. In phase I, the three process parameters viz cutting speed, feed rate and depth of cut were varied (Table I) to investigate their effects on SR, CF and PC of turned parts and subsequently to optimize the characteristics individually. A total of 81 experiments (three repetitions at each trial condition) were conducted according to the test conditions given in Table II. En24 steel rods (90 mm diameter and 500 mm length) were turned on an H-22 center lathe using TiC coated carbide inserts. The SR was measured by Philips roughness measuring equipment (PR9150) having a least count of 1 ru (0.025 m). The CF

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262

Figure 2. Flow chart of proposed algorithm for simultaneous optimization of multiple responses

Figure 3. Linear graph of L27 OA with factors and interaction assigned

Column Trial 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

A 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3

B 2 1 1 1 2 2 2 3 3 3 1 1 1 2 2 2 3 3 3 1 1 1 2 2 2 3 3 3

AB 3 1 1 1 2 2 2 3 3 3 2 2 2 3 3 3 1 1 1 3 3 3 1 1 1 2 2 2

AB 4 1 1 1 2 2 2 3 3 3 3 3 3 1 1 1 2 2 2 2 2 2 3 3 3 1 1 1

C 5 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

AC 6 1 2 3 1 2 3 1 2 3 2 3 1 2 3 1 2 3 1 3 1 2 3 1 2 3 1 2

AC 7 1 2 3 1 2 3 1 2 3 3 1 2 3 1 2 3 1 2 2 3 1 2 3 1 2 3 1

BC 8 1 2 3 2 3 1 3 1 2 1 2 3 2 3 1 3 1 2 1 2 3 2 3 1 3 1 2

9 1 2 3 2 3 1 3 1 2 2 3 1 3 1 2 1 2 3 3 1 2 1 2 3 2 3 1

10 1 2 3 2 3 1 3 1 2 3 1 2 1 2 3 2 3 1 2 3 1 3 1 2 1 2 3

BC 11 1 2 3 3 1 2 2 3 1 1 2 3 3 1 2 2 3 1 1 2 3 3 1 2 2 3 1

12 1 2 3 3 1 2 2 3 1 2 3 1 1 2 3 3 1 2 3 1 2 2 3 1 1 2 3

13 1 2 3 3 1 2 2 3 1 3 1 2 2 3 1 1 2 3 2 3 1 1 2 3 3 1 2

Optimizing multi-machining characteristics 263

Table II. Design matrix (L27 OA) with parameters and interactions

was measured with a three dimensional turning dynamometer which was pre-calibrated on a vertical milling machine. The PC was recorded with the help of a power meter. In phase II, the selected process parameters and their levels were the same as in phase I (Table I). In this phase of experimentation, 81 cutting edges (21 inserts, four edges each) of Widadur TG TiC coated carbide inserts were used according to the trial conditions specied in the L27 OA and given in Table II. Each experiment was replicated three times. The trials were conducted on En24 steel rods (90 mm diameter and 500 mm length) on H-22 center lathe to measure TL of carbide inserts. For TL assessment, ank wear width was measured at an interval of 1 min and the ank wear criterion of 0.45 mm against one TL was applied. The observed values of SR, CF, PC (phase I) and TL (phase II) are given in Table III. The analysis and optimal results Using Taguchis analysis and the ANOVA, the optimal settings of turning process parameters for SR, CF, PC and TL were obtained separately and the optimal values of the selected characteristics were predicted. The average values of the machining

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Trial no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Surface roughness (ru) R1 R2 R3 80 90 100 100 100 110 110 120 130 80 80 90 110 100 100 100 110 130 80 90 90 100 90 100 90 100 110 80 100 110 120 100 100 110 130 130 90 90 100 100 100 110 100 110 120 70 80 100 90 110 110 100 110 110 90 90 100 110 100 110 110 120 120 80 90 90 90 110 110 100 120 120 70 80 90 90 100 100 100 110 120

Tool life (min) R1 R2 R3 18 15 13 14 11 10 8 14 8 22 19 16 20 14 11 17 16 11 8 15 8 14 11 6 11 12 5 18 14 13 15 10 10 10 12 9 24 21 16 22 13 12 18 15 10 8 16 10 14 10 8 12 12 7 17 15 12 14 11 10 9 13 10 22 20 14 20 15 10 17 16 10 7 15 7 12 13 10 10 10 5

Cutting force (N) R1 R2 R3 336 427 493 435 459 558 463 516 617 354 472 486 375 506 505 413 542 549 347 370 470 373 418 508 392 441 572 395 438 484 416 492 538 410 504 573 349 423 417 389 423 536 412 511 526 322 361 528 346 444 511 367 498 551 358 430 504 377 460 564 428 482 549 369 437 435 362 484 479 409 546 555 334 412 467 361 434 505 390 460 589

Power consumption (kW) R1 R2 R3 1.064 1.352 1.561 1.378 1.454 1.767 1.466 1.634 1.954 1.475 1.967 2.025 1.563 2.108 2.104 1.721 2.258 2.288 1.793 1.912 2.428 1.927 2.16 2.625 2.025 2.279 2.955 1.251 1.387 1.533 1.317 1.558 1.704 1.298 1.596 1.815 1.454 1.763 1.738 1.621 1.763 2.233 1.717 2.129 2.192 1.664 1.865 2.728 1.788 2.294 2.64 1.896 2.573 2.847 1.134 1.362 1.596 1.194 1.457 1.786 1.355 1.526 1.739 1.538 1.821 1.813 1.508 2.017 1.996 1.692 2.275 2.313 1.726 2.129 2.413 1.865 2.242 2.609 2.015 2.377 3.043

264

Table III. Observed values of quality characteristics

characteristics at each level and against each parameter were calculated and are reported in Table IV. The summary results are given in Table V. Table V displays the individual optimal values of the selected characteristics and corresponding optimal settings of the process parameters for En24 steel turned parts using TiC coated carbide inserts.
Average values of CF (N) L1 471 415 381 452 458 456 L2 454 454 459 457 453 449 L3 436 491 521 452 450 456

Average values of SR (ru) Process parameter designation A B C AB BC AC L1 106.3 88.1 94.4 101.1 100.4 101.9 L2 101.1 102.6 101.1 100.0 100.9 100.7 L3 95.9 112.6 107.8 102.2 102.0 100.7

Average values of TL (min) L1 12.33 14.93 14.85 13.31 12.56 12.69 L2 16.33 12.59 14.00 12.81 13.31 12.67 L3 10.22 11.37 10.04 12.76 13.02 13.54

Average values of PC (kW) L1 1.490 1.722 1.572 1.891 1.898 1.923 L2 1.892 1.877 1.898 1.890 1.872 1.864 L3 2.252 2.036 2.165 1.891 1.865 1.849

Table IV. Average values of quality characteristics at different levels

Preference scale construction Surface roughness X* X

0

optimum value of SR 76.18 ru (refer to Table V) minimum acceptable value of SR 130 ru (assumed, as all the observed values of SR in Table III are in between 70 and 130 ru)

Optimizing multi-machining characteristics 265

Using these values and the equations (4) and (5), the preference scale for SR was constructed as P SR 38:78 log Tool life X* X
0

X SR 130

optimum value of TL 20.19 min (refer to Table V) minimum acceptable value of TL 5 min (assumed, as all the observed values of TL in Table III are in between 5 and 25 min)

The preference scale for TL was constructed as: P TL 14:85 log X TL 5 9

Cutting force X* X0 optimal value of CF 324.88 N (refer to Table V) minimum acceptable value of CF 620 N (assumed, as all the values of CF in Table III lie in between 320 and 620 N)

Using these values in equations (4) and (5), the preference scale for CF has been constructed as: P CF 232:10 log X CF 620 10

Quality characteristic SR TL CF PC

Optimal settings of process parameters A3 B1 A2 B1 A3 B1 A1 B1 C1 C1 C1 C1

Signicant process parameters (at 95 percent condence level) A, A, A, A, B, B, B, B, C C C C

Predicted optimal value of quality characteristics 76.18 ru 20.19 min 324.88 N 1.028 kW

Note: Subscripts represent levels of the process parameters

Table V. Optimal settings of process parameters (phase I and II) and optimal values of individual quality characteristics

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Power consumption X* X0 optimum value of PC (when optimized individually) 1.028 kW (Table V) minimum acceptable value of PC 3.050 kW (assumed, all the PC values in Table III are in between 1.060 and 3.050 kW) X PC 3:050

266

Using these values, the preference scale for PC has been found to be: P PC 219:06 log 11

Weight of quality characteristics The weights to the selected quality characteristics were assigned as given below: WSR weight assigned to SR 0.25 WCF weight assigned to CF 0.25 WTL weight assigned to TL 0.25 WPC weight assigned to PC 0.25 It has been assumed that all the quality characteristics are equally important and hence equal weights have been assigned. However, there is no constraint on the weights and it can be any value between 0 and 1 subject to the condition specied in equation (6). The customers requirements and priorities should be taken into consideration while deciding the weights of quality characteristics. Utility value calculation The utility value of each turned part was calculated using the following relation (overall utility function): U n; R P SR n; R W SR P CF n; R W CF P TL n; R W TL P PC n; R W PC where, n trial number, n 1, 2, . . . , 27; R replication number, R 1,2,3 The utility values thus calculated are reported in Table VI. Analysis of the data and determination of optimal settings of process parameters The data (utility values) were analyzed both for mean response (mean of utility at each level of each parameter) and signal-to-noise (S/N) ratio. Since utility is a higher the better (HB) type of characteristic, (S/N)HB has been used (Ross, 1996): " # R 1X 1 S=N HB 210 log 13 R j1 y2 j where, yj value of the characteristic at observation j; R number of replications in a trial. 12

The S/N ratios are also given in Table VI. The mean responses and main effects in terms of utility values are calculated and reported in Table VII. The average values of S/N ratios and the S/N main effects are also calculated and reported in Table VIII. The data from Tables VII and VIII are plotted in Figure 4. It is clear from the Figure 4 that the second level of cutting speed (A2), the rst level of feed (B1) and the rst level of depth of cut (C1) would yield best performance in terms of utility value and S/N ratio within the selected range of parameters.

Optimizing multi-machining characteristics 267

R1 8.43 6.30 4.83 5.64 4.95 3.32 4.00 3.93 1.70 7.88 6.05 5.13 6.07 4.23 3.86 5.67 3.67 2.28 6.07 6.09 3.75 5.48 4.90 2.39 5.27 4.72 1.11

Raw data (utility values) R2 7.52 5.60 4.52 5.24 4.42 3.91 5.03 3.47 2.29 7.61 6.32 5.52 6.42 5.10 3.27 5.78 3.88 2.71 6.90 6.82 3.01 6.35 3.57 2.43 5.32 3.22 1.79

R3 7.48 6.27 4.57 6.03 4.94 3.26 4.62 4.19 3.04 7.66 6.08 5.53 7.13 4.19 3.60 5.74 3.27 2.42 6.49 5.97 3.56 5.86 4.52 3.26 4.70 3.38 1.52

S/N ratios (dB) 17.81 15.61 13.32 14.98 13.53 10.79 13.04 11.66 6.68 17.75 15.77 14.62 16.25 12.97 11.01 15.16 11.08 7.79 16.20 15.93 10.61 15.37 12.49 8.35 14.10 11.18 2.85

Table VI. Utility data based on quality characteristics (a) SR (b) TL (c) CF (d) PC

Process parameters designation A B C AB BC AC

L1

Average utility values L2 L3 5.08 4.61 4.82 4.73 4.79 4.75 4.35 3.62 3.24 4.70 4.74 4.84

Main effects L2-L1 L3-L2 0.28 21.39 21.34 20.07 0.09 0.12 2 0.73 2 0.99 2 1.58 2 0.03 2 0.05 0.09

4.80 6.00 6.16 4.80 4.70 4.63

Table VII. Average values and main effects (raw data: SR, CF, TL and PC)

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The pooled versions of ANOVA for raw data (utility) and S/N ratio are given in Tables IX and X, respectively. It is clear from the Tables IX and X that feed (B) and depth of cut (C) affect signicantly the variation of utility value since these are signicant in both the ANOVAs. The Table IX also reveals that the relative power of depth of cut (C: 51.82 percent) and feed (B: 34.61 percent) is signicantly quite larger
Average S/N values L2 L3 13.60 12.86 13.36 12.60 12.56 12.60 11.35 9.85 9.01 12.78 13.27 13.10 S/N main effects L2-L1 L3-L2 0.55 22.43 22.27 20.02 0.39 0.30 2 2.25 2 3.01 2 4.35 0.18 0.71 0.50

268
Process parameters designation A B C AB BC AC L1 13.05 15.29 15.63 12.62 12.17 12.30

Table VIII. Average S/N values and main effects (raw data: SR, CF, TL and PC)

Figure 4. Effects of process parameters on utility value and S/N ratio (the main effects)

Source A B C AB BC AC T e (pooled)

SS 7.253 77.169 115.251 (0.426) (0.393) 2.934 221.280 (18.673)

DOF 2 2 (4) (4) 4 80 (70)

V 3.627 38.585 57.626 0.734 0.267

F ratio 13.58 * 144.51 * 215.83 * Pooled Pooled 2.75 *

SS0 6.677 76.593 114.675 1.782 221.280 21.553

P 3.02 34.61 51.82 0.81 100.00 9.74

Optimizing multi-machining characteristics 269

Notes: SS Sum of squares, DOF Degrees of freedom, V Variance, SS0 =Pure sum of squares, P Percent contribution, T=Total, e error, A Cutting speed, B Feed, C Depth of cut; *Signicant at 95 percent condence level; F 0.05;2;70 3.13 (tabulated); F0.05;4;70 2.50 (tabulated)

Table IX. Pooled ANOVA (raw data: SR, CF, TL and PC)

Source A B C AB BC AC T e (pooled)

SS (24.689) 133.841 203.466 (2.330) (15.157) (15.350) 444.111 (106.804)

DOF (2) 2 2 (4) (4) 4 26 (22)

V 66.921 101.733 4.855

F ratio Pooled 13.78 * 20.95 * Pooled Pooled Pooled

SS0 121.521 191.146 444.111 131.444

P 27.36 43.04 100.00 29.60

Notes: *Signicant at 95 percent condence level; F0.05;2;22 3.44 (tabulated)

Table X. Pooled S/N ANOVA (raw data: SR, CF, TL and PC)

than the relative power of cutting speed (A: 3.02 percent) and interaction between cutting speed and depth of cut (A C: 0.81 percent) in affecting the utility value. The cutting speed (A) and the interaction between cutting speed and depth of cut (A C) are signicant in ANOVA for raw data only, hence affect the mean utility value. The optimal setting of the turning process parameters for the multi-characteristics optimization (SR, TL, CF and PC) of En24 steel turned parts using TiC coated carbide inserts is given in Table XI. Predicted means (optimal values of quality characteristics) Surface roughness  The average values of SR at the second level of cutting speed A2 ; the rst level of feed   1 and the rst level of depth of cut C1 are given in Table XII. The overall mean of B  SR TSR is 101.11 ru. The predicted mean (optimal value) of SR (mSR) is:
Cutting speed * (A2, second level) Feed * (B1, rst level) Depth of cut * (C1, rst level) Note: *Signicant at 95 percent condence level 250 m/min 0.14 mm/rev 0.70 mm

Table XI. Optimal settings of process parameters

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    mSR A2 B1 C1 2 2TSR 81:38 ru The 95 percent condence interval of conrmation experiments (CICE) was calculated by using the following equation (Ross, 1996): s   1 1 Ve 14 CICE F a 1; f e neff R where, Fa(1, fe) the F-ratio at a condence level of (1 2 a) against DOF 1 and error degree of freedom, fe; neff N R Ve
N 1Total DOF associated in the estimate of mean ;

270

total number of results; sample size for conrmation experiment; error variance.

The specic values as required in equation (14) are: f e error DOF 70; V e error variance 36:720 N 81; R 3; neff 81=7calculated

F 0:05 1; 70 3:98Tabulated F value

So, CICE ^ 7.83 The predicted optimal range (for a conrmation run of three experiments) of SR is: 73:55 , mSR ru , 89:21 Tool life  The average values of TL at the second level of cutting speed A2 ; the rst level of   1 and the rst level of depth of cut C1 are given in Table XII. The overall feed B  mean of TL TTL is 12.96 min. So, the predicted mean of TL (mTL) is:     mTL A2 B1 C1 2 2TTL 20:19 min:

Levels Table XII. Average values of quality characteristics at optimum levels A2 B1 C1

SR (ru) * 101.1 88.1 94.4

TL (min) * 16.33 14.93 14.85

CF (N) * 454 415 381

PC (kW) * 1.892 1.722 1.572

Note: *The above average values are taken from Table IV

The 95 percent condence interval of conrmation experiments (CICE) was calculated by using the following values in equation (14): f e error DOF 62; V e error variance 2:277 N 81; R 3; neff 81=7calculated

Optimizing multi-machining characteristics 271

F 0:05 1; 62 4:00tabulated F value

So, CICE ^ 2.16 The predicted optimal range (for a conrmation run of three experiments) of TL is: 18:03 , mTL min , 22:35 Cutting force  The average values of CF at the second level of cutting speed A2 ; the rst level of feed   1 and the rst level of depth of cut C1 are given in Table XII. B  The overall mean of CF TCF is 453.56 N. So, the predicted mean of CF (mCF) is:     mCF A2 B1 C1 2 2TCF 342:88 N The 95 percent CICE (for three conrmation experiments) of the predicted mean has been calculated using equation (14). The specic values as required in equation (14) are: f e error DOF 70; V e error variance 488:49 N 81; R 3; neff 81=7calculated

F 0:05 1; 70 3:98Tabulated; from F Table

So, CICE ^ 28.57. The predicted optimal range (for a conrmation run of three experiments) of CF is: 314:31 , mCF N , 371:45 Power consumption  The average values of PC at the second level of cutting speed A2 ; the rst level of feed   B1 and the rst level of depth of cut C1 are given in Table XII.  The overall mean of PC TPC is 1.878 kW. So, the predicted mean of PC (mPC) is:     mPC A2 B1 C1 2 2TPC 1:43 kW The 95 percent CICE (for three conrmation experiments) of the predicted mean has been calculated by using the following values in equation (14): f e error DOF 70; V e error variance 9:87243 1023 N 81; neff 81=7calculated

JMTM 17,2

R 3;

F 0:05 1; 70 3:98tabulated; from F table

So, CICE ^ 0.128. The predicted optimal range (for a conrmation run of three experiments) of PC is: 1:302 , mPC kW , 1:558

272

The values of the error DOF and the error variance for all the above calculations have been taken from the pooled ANOVAs of raw data (not reported here) when the quality characteristics are optimized individually by Taguchis approach. Conrmation experiments Three conrmation experiments were conducted at the optimal settings of turning process parameters. The following average values have been found for the quality characteristics considered: . Average SR 83.33 ru . Average CF 358 N . Average TL 21.67 min . Average PC 1.489 kW These average values of the quality characteristics are lying within the 95 percent CICE of the optimal range. Summary results and comparison with single characteristic optimization The summary results and comparison with single characteristic optimization are reported in Table XIII. Conclusions . A simplied model based on Taguchis approach and utility concept is used to determine the optimal settings of the process parameters for a multi-characteristic product. The model is used to predict optimal settings of turning process parameters to yield the optimum quality characteristics of En24 steel turned parts using TiC coated carbide inserts.
Method Single characteristic optimization Characteristic SR TL CF PC SR, TL, CF, PC Optimal condition A3 *, A2 *, A3 *, A1 *, A2 *, B1 *,C1 * B1 *,C1 * B1 *,C1 * B1 *, C1 * B1 *,C1 * Optimal value 76.18 ru 20.19 min 324.88 N 1.028 kW SR 81.38 ru TL 20.19 min CF 342.88 N PC 1.43 kW

Multi-characteristic optimization

Table XIII. Summary and comparison results

Notes: Quality characteristics: surface roughness (SR), tool life (TL), cutting force (CF), power consumption (PC); Weights: WSR 0.25, WTL 0.25, WCF 0.25, WPC 0.25; Type: LB, HB, LB, LB, respectively; *Signicant at 95 percent condence level

The optimal values obtained using the multi-characteristic optimization model have been validated by conrmation experiments. The weights assigned to the selected quality characteristics have been assumed equal. However, with a different set of weights, a different set of optimal parameters for the quality characteristics will result. The optimal set predicted will be closer to the optimal set predicted for the single characteristic which is having the largest weight. The model can be extended to any number of quality characteristics provided proper utility scales for the characteristics are available from the realistic data.

Optimizing multi-machining characteristics 273

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Singh, H. and Kumar, P. (2003b), Investigation of the effect of process parameters on power consumption for turned parts through RSM, E-proceedings of International Conference on CAD,CAM,ROBOTICS and Autonomous Factories, IIT Delhi, India. Singh, H. and Kumar, P. (2003c), Cutting force optimization of turned parts by Taguchis technique, Proceedings of the XIII National Conference of Indian Society of Mechanical Engineers, IIT Roorkee, India. Singh, H. and Kumar, P. (2004), Tool wear optimization in turning operation by Taguchi method, Indian Journal of Engineering and Materials Sciences, Vol. 11, pp. 19-24. Singh, H., Kumar, P. and Singh, I.P. (2001a), Effect of process parameters on surface roughness of turned parts using response surface methodology, paper presented at International Conference on Mathematical Modelling, University of Roorkee (now IIT), Roorkee, pp. 483-9. Singh, H., Kumar, P. and Singh, I.P. (2001b), Tool life prediction by response surface methodology, paper presented at XII National Conference of Indian Society of Mechanical Engineers (ISME), Chennai, India, pp. 262-5. Su, C.T. and Tong, L.I. (1997), Multi-response robust design by principal component analysis, Total Quality Management, Vol. 8 No. 6, pp. 409-16. Taraman, K. (1974), Multi machining output-multi independent variable turning research by response surface methodology, International Journal Production Research, Vol. 12, pp. 232-45. Tarang, Y.S., Yang, W.H. and Juang, S.C. (2000), The use of fuzzy logic in the Taguchi method for the optimization of the submerged arc welding process, International Journal Advanced Manufacturing Technology, Vol. 16 No. 9, pp. 688-94. Tong, L.I., Su, C.T. and Wang, C.H. (1997), The optimization of multi-response problems in the Taguchi method, International Journal of Quality & Reliability Management, Vol. 14 No. 4, pp. 367-80. Further reading Tsui, K.L. (1999), Robust design optimization for multiple characteristics problems, International Journal Production Research, Vol. 37, pp. 433-45. Corresponding author Hari Singh can be contacted at: hsingh_nitk@rediffmail.com

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