University of Engineering and Technology Peshawar (Jalozai

Campas)

1. Muhammad Sohaib. (19JZIND0122)

2. Muhammad Bilal. (19JZIND0121)
Submitted By 3. Shafiullah. (19JZIND0125)
4. Moiz Ali. (19JZIND0124)
5. Umais Ahmad. (19JZIND0123)
6. Farisa Mumtaz. (19JZIND0126)

Submitted To Engr. Mohsin Iqbal Qazi

Course IE-321 Design Of Experiments

Date 19th January,2023

Department Indusrtrial

Group 3

CEP Title:
 FULL FACTORIAL DESIGN FOR OPTIMIZATION OF PRODUCTION
PROCESS BY TURNING MACHINE
Objectives:

• To enhance our knowledge about the use of Full Factorial Design.

• To know the practical usage & application of DOE subject.
• To perform full Factorial Design Analysis on Optimization of Production Process by Turning
Machine.
• To learn the use of Minitab & interpret the results.
Introduction:
Design of Experiment:

We can ascertain the individual and interaction effects of many elements that can affect the
output results of your measurements by using Design of Experiments (DOE) methodologies.
DOE can also be used to learn more and determine the ideal circumstances under which a
system, process, or product should operate.

DOE is applicable to a wide range of inquiry objectives, but it can be particularly crucial early on
in a screening study to assist you identify the most crucial elements. Then, it may assist you in
optimizing and better comprehending how the most crucial variables that you can control affect
the responses or vital quality features.

Figure#1: DOE.

Full Factorial Design:

Full Factorial Design leads to experiments where at least one trial is included for all possible
combinations of factors and levels. This exhaustive approach makes it impossible for any
interactions to be missed as all factor interactions are accounted for. The thoroughness of this
approach, however, makes it quite expensive and time-consuming for experiments with multiple
factors – and this increases exponentially with the number of factors and levels.

Figure#2: Full Factorial Design.

Analysis of Variance (ANOVA):

Analysis of variance (ANOVA) is an analysis tool used in statistics that splits an observed
aggregate variability found inside a data set into two parts: systematic factors and random
factors. The systematic factors have a statistical influence on the given data set, while the
random factors do not. Analysts use the ANOVA test to determine the influence that independent
variables have on the dependent variable in a regression study.

Figure#3: ANOVA.
Problem Statement:
Three level Full Factorial Design has been employed to study the effect of different experimental
variables on the production of paddy husker machine. Three variables of spindle of speed (200,
220, and 270 rpm), flow rate (0.25, 0.36, and 0.45 mm/rev), and depth of cut (0.3, 0.5, and 0.7
mm.) were used to identify the significant effects and interactions in the batch studies. A
polynomial regression model has been developed using the experimental data. The results show
that production process of turning machine was strongly affected by the variations in spindle of
speed, flow rate, and depth of cut.

Response Variable: Material Removing Rate is the main response variable which is being
analyzed against the three driving factors like spindle speed, flow rate & depth of cut. There are
three factors and every factor has three levels.

Experimental Design:
The parameters study is performed in a three-level three-parameter design 33. In this study
spindle of speed, feed rate and depth of cut by experimenting with aluminum alloy grade 6063
T5 was selected as control factors and their levels are shown in Table 1.1.
Parameters
Level Spindle Speed(rpm) Feed Rate(mm/rev) Depth of Cut(mm)
1 200 0.25 0.3
2 220 0.36 0.5
3 270 0.45 0.7
Table# 1.1

1. Hypothesis:

H0: μ1 = μ1 = ... = μk = 0

H1: μ j ≠ 0 for at least one j different than zero.

2. Mathematical Model:
Yk = β0 + β1x1+ β1x1 + β2x2 + β3x3 + β12x1x2 + β13x1x3 + β21x2x1 + β22x2x2 + β23x2x3 + β31x3x1 + β32x3x2 + β33x3x3
+ β123x1x2x3

Here Y is the response, the Q is the coefficient that have calculated using an appropriate method such
as least square method. The variables x1x2 and x3 are coded as 1.0 and -1, for the high, medium and
low levels for their respective factors. The interaction between x 1x2 and x3 is denoted as x2x1, x2x3,
x3x1, x3x2 and x1x2x3 the other interactions effects are similarly defined.

3. Data validity:
 3.1) Normality: The check of the normality assumptions of the data is then conducted, it
can be seen in Fig. 3 that all the points on the main effect plot come close to forming a straight
line. This implies that the data are fairly normal and there is no deviation from the Normality.

Figure#3: Normality Graph.

3.2) Independence of Data: The following graph shows that data is behaving
independently as there are no cyclic patterns observed & the data is said to be normal.

Figure#4: Data Independent.

3.3) Data Variance: Looking at Fig.5 we can say that there is no variance amongst the data
& equally distributed. Thus all the criteria for data validity are satisfied & hence data is
valid.

Figure#5: Data Variance.

ANNOVA Assumptions:
There are three primary assumptions in ANOVA:

1. The responses for each factor level have a normal population distribution.
2. These distributions have the same variance.
3. The data are independent.

Procedure:
1. To perform the Full Factorial Test, open the MINITAB software.

2. Now go to stats click on DOE, select Factorial< Create Factorial.

Figure#6: Factorial.

3. Now a new box will open so select the Full factorial with three factors.

Figure#7: Factorial.
4. Now click on design & enter the data as shown in figure below. Give replication of value 3.

Figure#8: Design Data.

5. After it click on factors & give values to the factors & uncheck the randomize run box.
 Figure#9: Data Entry.
6. Now by clicking OK we will get the worksheet with factors mentioned. Now just enter the
response values in front of every replication. We will have the total of 81 data values.
2

Figure#10: Worksheet.
 7. Now again go to Stats>DOE>Factorial>Analyze Factorial. So new window will open in
response section select the response & select the residual plots.

Figure#11: Analyzing.
8. After clicking on the OK, we will get the results which are discussed below.

Results Discussion:
DOE and full factorial design. The DOE simulation was accomplished with two parameters:
spindle of speed (SS), flow rate (FR), and depth of cut (DC) respectively. It was performed
according and production process by turning machine. A model fitting was accomplished for the
first 81-full factorial. The analysis of variance (ANOVA) was used to evaluate the adequacy of
the fitted model.

1. ANOVA Results: The following figure shows the ANOVA results. It consists of SS & P-value
for all factors & their interaction. The P-value identifies what factors are significant & what are
insignificant. Our Confidence interval is 95% so if any P-value is greater than 0.05 than that
factor will be insignificant. So looking at the results all the factors & its interaction are
significant.
2. Significant Factors: All the terms including the main effect terms such as feed, depth and speed,
and interaction terms are significant.
3. Insignificant Factors: There is no insignificant term since all the terms are significant.
 Figure#12: Results.

4. Percent Contribution:

Figure#12: Percent Contribution.

5. R-Square value: The R-square value (determination coefficient) provided a measure of how
much of the variability in the observed response values could be explained by the experiment
factors and their interactions
6. Main Effects: Go to Stats>ANOVA> Main Effects Plot. We will get a new window & enter data
as below.

Figure#13: Main Effect Plot.

Optimal Setting:
So with spindle speed 200, feed 0.36 & depth 0.7 settings, we will get the highest value of
response i.e. the Material Removing Rate in Turning Operation.

7. Regression Analysis: Go to Stats> Regression> Regression> Regression Fit Model & a new
window will open & add the data as below.
The regression equation identifies that the feed & depth have positive response on Response
variable & Spindle speed has negative effect on MRR.
 Figure#14: Regression Analysis.

8. Interactions: For interaction go to Stats>ANOVA>Interactions. So the following figure shows

the 3*3 interactions. Its briefly describes the full interactions amongst the factors & their levels.

Figure#15: Interactions Plot.

Conclusion:
Full factorial design is an efficient strategy for optimizing material removal rate, according to the
study's findings. Spindle speed, flow rate, and cut depth were effectively optimized using the
Response Surface Methodology. When productions into the formulation, the optimized levels of
R-Squire (adjust) was 99.99 % and standard deviation was 0.0035189 yielded lowest material
removal rate. This study unequivocally shown that complete factorial design was one of the
effective strategies for determining the ideal conditions for maximizing the removal of lath. The
ideal point was located using a contour plot and a graphic response surface. In order to properly
optimize the manufacturing process by rotating the machine, statistical fitted models and the
contour plot of responses may be utilized to forecast values of responses at any position inside
the experimental space.