29

Chapter-2

LITERATURE
SURVEY
 30

CHAPTER - 2

LITERATURE SURVEY

S.No. Name of the Sub-Title Page No.

2.1 Overview 31

2.2 Welding and Allied Processes 32

2.3 Conventional and Non-Conventional Machining Processes 41

2.4 Other Productive and Non-Productive Processes 50

 31

LITERATURE SURVEY
2.1 Overview

An extensive survey of the existing literature has was carried

out to uncover the progress of research in the focal area and in the

direction of the present work.

The quality of welding depends on the combination of various

process parameters that depends on the selection of the process

parameters. In robot welding, the welding path is taught to the robot

by a teach pendant and the weld quality is further improved by

selecting the appropriate process parameter values by trial and error

method. The selection of optimum process variables is possible by two

methods. The first method is an empirical method that takes into

account the experience of welders and welding engineers. This method

is inadequate to explain the relationship between the input and the

output of the process. The second method is based on the design of

experiments and mathematical models. In this method, it is possible

to relate the output variables (quality characteristics) and the input

variables (process variables) based on scientific and statistical

grounds.

The literature survey reveals studies and investigation projects

carried out as per the second method of optimization, i.e., selecting

the process variables for the intended application in welding and other

manufacturing processes.
 32

The review of literature reveals that the optimization of process

parameters has been carried out for various manufacturing processes

like casting, machining, welding and even for non- productive

processes like consumer electronics. The welding parameters have

been optimized for various objectives like strength, bead dimensions,

penetration, distortion and other similar process quality objectives. An

appreciable amount of research work has been published in the

production of leak-free welding joints; however, not much work has

been done to understand the optimization of welding parameters to

produce leak-free joints.

Taguchi method provide an efficient and systematic way to

optimize the design for performance, quality and cost. Taguchi

methods have been used successfully in Japan and the United States

in automobile and consumer electronic sectors [25]. The literature

survey presented here is grouped under the following sub-headings.

i. Welding and allied processes

ii. Conventional and non-conventional machining processes

iii. Other productive and non-productive processes

2.2 Welding and Allied Processes

Naidu et al. [26] have made a statement that the modeling of a

welding process generally means the derivation of a set of

mathematical equations describing the physical process by means of

the fundamental principles of scientific or statistical or experimental

techniques. The model describes the behavior of the system to be

controlled.
 33

Kumanan and Dhas [27] revealed that technologies could be

utilized to measure, control and optimize the Submerged Arc Welding

(SAW) process parameters to obtain a good quality of weld. They have

used multiple regression analysis, artificial neural network and

response surface methodology to model the process.

Shiva et al. [28] proposed a model for plasma transferred arc

surfacing. The model describes welding current, oscillation width,

travel speed, pre-heat temperature, power, feed rate and response

variable penetration. In the study, the central composite rotatable

design was used to conduct the experiments.

Bolinger [29] reported that welding is more complex than any

other manufacturing processes, as it involves complex interactions of

solid, liquid, gaseous and plasma state phenomena. Further, the

entire process takes place simultaneously in relatively small volumes

and over a short period of time. Thus, to relate the inputs and the

outputs of the welding process, the scientific means of measuring,

controlling and optimizing the variables are essential to exploit the

welding technology.

Jayaram and Siva [30] reported the use of Taguchi methods to

optimize the stir welding process parameters to weld aluminum alloy

A319. The parameters, such as rotational speed, welding speed and

axial force, were optimized to achieve the maximum tensile strength at

three levels for each parameter. Experiments were conducted as per

the L8 Orthogonal Array and Analysis of Variance (ANOVA) was also

applied to determine the contribution of each parameter.

 34

Kannan and Murugan [31], reported that stainless steel

cladding by flux cored arc welding contains some amount of delta

ferrite and the control of which is very essential, else it could lead to

inferior mechanical and corrosive resistance properties. To reduce

delta ferrite, the authors had optimized the process by the central

composite rotatable design. The process parameters were welding

speed, distance between nozzle and plate, welding current and torch

angle - with each parameter having five levels. Mathematical models

were developed by using regression coefficients, coefficients are

calculated by using the six sigma concept and were verified by the

Systat software.

Although Resistance Spot Welding (RSW) is a well-established

process in the automotive industry, according to Cho and Hu [32] a

serious concern exists with the welding of aluminum by RSW as it has

high conductivity, narrow range of temperature between solidus and

liquidus state, low melting point and non-conductive film on the

surface. The authors overcame the challenges by using robust

operating parameters obtained from the design of experiments.

Mathematical models were also developed to predict the results.

Ericson and Nylen [33] optimized robot welding speed to get

complete penetration of welding joint. Optimization is not done by

actual conduction, instead it is done by integrating robot simulation,

finite element analysis and numerical optimization.

Vel and Gunaraj [34] developed a mathematical model to

predict the angular distortion of the welding of steel plates. The

 35

coefficients of the model were tested for significance and the model

was validated by drawing curves for the predicted and the actual

values of distortion.

Amar et al. [35] applied the Taguchi methods to optimize the

SAW process parameters for the hard facing process. The welding

process parameters were arc current, arc voltage, welding speed,

electrode stick-out and pre-heat temperature. Orthogonal array L27

(313) was used. The parameters were optimized for deposition rate,

dilution and hardness. Interactions between arc current, arc voltage

and welding speed were studied for all the three objectives.

Kim et al. [36] in their investigation, applied controlled random

search to optimize Gas Metal Arc (GMA) welding for complete

penetration of 4 mm thick mild steel plates.

In order to obtain the optimal tensile properties, Bala et al. [37]

investigated the Tungsten Inert Gas (TIG) welding process parameters.

The authors used the Taguchi technique to study all the parameters’

range using few experiments. Orthogonal array L16 (44) was adopted

with the process parameters peak current, base current, pulse

frequency and pulse time. Each parameter range was split into four

levels and 16 experiments were conducted as per the orthogonal

array. However, interactions between the process parameters were not

considered. ANOVA tool was also used to identify the factor, which

significantly affected the tensile properties.

Ghen et al. [38] optimized the process parameters of laser

engraving by using the Taguchi fractional factorial experiments. The

 36

engraving was done on glass substrate coated with a film. The selected

process parameters were beam expansion ratio, focal length, laser

power, pulse repetition rate and speed of engraving. The objective of

this experimentation was to get an engraved line with a minimum

width of 18μm. L16 (24) OA was used and no interactions were studied.

Signal to Noise ratio (S/N) for the response was also calculated using

lower-the-best characteristic. ANOVA was also used to calculate the

contribution of each parameter.

Gunaraj and Murugan [39] optimized the SAW process

parameters to get an optimal weld bead volume. In this study, the

central composite rotatable design was adopted. The selected

parameters were welding voltage, wire feed rate, welding speed and

nozzle to plate distance. A mathematical model was developed to

predict the weld bead dimensions by the use of MATLAB. Welding was

performed on pipes without considering the interactions.

Mishra and Debroy [40] developed six feed-forward neural

networks, which were based on genetic algorithms and gradient-

descent for Gas Tungsten Arc (GTA) welding. To develop the neural

network models, 17 input variables, which included the welding

process parameters and the important material properties, were

considered,. The output variables of the models were depth, width,

length of the weld pool, peak temperature, cooling time and minimum

liquid velocity in the weld pool.

Palaniradja et al. [41] analyzed the influence of various process

variables of gas carburizing on the surface hardness. The variables

 37

selected were holding time, carbon potential, carburizing temperature

and quenching time. For each parameter, three levels were fixed.

Based on the number of factors and their levels, L9 (34) orthogonal

array was selected and ANOVA was also applied to determine the

influence of parameters. It was found that the percentage of

contribution in holding time was 56%, indicating that quenching time

had the most influence on surface hardness.

Ic et al. [42] conducted 23 full factorial experiments to study

responses, such as yield point, tension or compression strength and

modulus of elasticity of GMA welding. The process variables were

welding groove angle, groove geometry and type of load on welding.

For all these responses, mathematical models were developed using

the Minitab software.

Ramasamy et al. [43] employed design of experiments approach

to study the influence of factors of drawn arc welding of steel sheets.

The chief quality responses used for the study were tensile strength,

shear strength, torque to failure and bending angle to failure. In this

investigation, the authors had placed more importance on general

manufacturing variables than the inherent process variables. The

process variables selected for the examination were polarity, type of

coating, thickness of material, stud design, stud coating, collet wear,

power type and surface condition. A 32- trial of design of experiments

was selected with two interactions. The effects of factors were

estimated by ANOVA, and the regression models were developed for all

of the four chief quality responses.

 38

Sapakal and Telsang [44] analyzed operating or process

parameters of Metal Inert Gas welding to attain full depth of

penetration. In this study they studied the influence process

parameters on penetration. For the investigation, the selected

parameters were welding current, welding voltage and welding speed.

Each parameter range was split into three meaningful levels. Based

on number of factors and their levels L9 OA was selected. No

interactions were considered, however ANOVA computations were

calculated to estimate contribution of factors. It is found that

contribution of welding voltage was higher (84.42%) than welding

speed (6.83%) and welding current (3.84%). Test experiments were

also conducted to confirm the results.

Siva et al. [45] observed that variation in quality can be

controlled by making a robust process. As the variation of quality is

considerably higher in welding than in any other manufacturing

process, the application of a robust design of parameters improves the

quality of welding.

Companelli et al. [46] studied the effect of friction spot welding

parameters such as rotational speed, plunge depth and dwell time on

the lap shear strength of AZ31 magnesium alloy joints. The

optimization of the input process parameters was carried out by the

use of the L9 OA. ANOVA computations was used to estimate the effect

of each factor. It was found that the contribution of plunge depth was

more (57.48%) compared to other factors.

 39

Haragopal et al. [47] employed the Taguchi method to design

process parameters that optimize the mechanical properties of

aluminum alloy used for construction of aerospace wings. The

selected parameters of the Metal Inert Gas (MIG) welding process were

pressure, current, grove angle and pre-heating. Experiments were

conducted as per the L9 OA. ANOVA computations revealed that

current was the most influencing parameter on the ultimate tensile

strength with a contribution of 57.5% at 99% confidence level.

Ramirez and Johnson [48] studied the effects of arc length,

welding current, welding length and conditions of the cellulose

electrode (as received or dried) on the enrichment of alloying elements

in the deposited weld metal. Experiments were not conducted as per

any OA, but were instead conducted in three sets. The outcome of this

investigation was that the arc length, weld length (time) and dried

condition of the electrode had a primary effect on the chemical

composition of the deposited weld metal.

Purohit and Digamber [49] employed the L25 OA to optimize the

process parameters of SAW, in order to to obtain the desired bead

dimensions. The S/N ratio were calculated to understand the process

and the contributions of various factors like welding current, arc

voltage, welding speed and nozzle to plate distance.

Ismail and Taha [50] employed the Taguchi optimization

technique to optimize the process parameters of plasma arc surface

hardening process. The selected parameters were arc current,

scanning velocity and carbon content. Experiments were conducted as

 40

per the L8 OA. Optimum parameters were decided by the aid of the

S/N ratio and ANOVA computations.

Vinod [51] optimized the SAW process parameters by using the

Taguchi technique. The selected parameters were voltage, current,

welding speed and basicity index. ANOVA was applied to find the

contribution of various parameters, significance was also tested by t-

test. Regression models for all objective functions were developed and

validations of the models were also done.

Pawan et al. [52] optimized the GTA welding process parameters

to weld aluminum alloys. Five parameters were selected and

experiments were conducted as per the L25 OA.

Thakur and Nandedkar [53] optimized the process parameters

of RSW. The selected parameters were pressure, welding time and

current. The objective function was to maximize the tensile strength.

Experiments were conducted as per the L27 OA and the work piece

was Stainless Steel AISI304.

Antonio et al. [54] optimized the process parameters of MIG

welding. The selected parameters were voltage, speed, arc oscillation,

gun orientation, shielding gas and filler metal. The objectives were to

evaluate the percentage of dilution and ratio between reinforcement

and bead width. Experiments were conducted as per the L9 OA.

Rao et al. [55] attempted to find a solution to the alloying of

RSW sheets with electrode and the subsequent deterioration of

welding quality and the wear of electrode. This problem was

minimized by optimizing the shear strength of RSW sheets. For this,

 41

the Taguchi optimization technique was employed. The selected

parameters were welding current, weld time, electrode diameter and

welding force. Experiments were conducted as per the L27 OA and the

optimum parameters were decided with the help of ANOVA.

Edwin [56] optimized the process parameters for SAW to obtain

the required bead dimensions. For this investigation, the L9 OA was

used and the selected parameters were welding current, arc voltage,

welding speed and electrode stick. Multiple regression models were

developed to predict the quality of weld.

Catarina and Virginia et al. [57] optimized the process

parameters for improvement of friction stir welded joints of the

aerospace aluminum alloy. The authors had employed the Taguchi

method for optimization of the selected parameters, namely, forging

force, travel speed and pin length.

Sathiya and Abdul [58] employed the grey-based Taguchi

method to optimize the laser welding parameters with the objective of

reaching the required bead geometry.

Dhas and Kumanan [59] optimized the parameters of SAW to

obtain consistent weld quality. For this investigation, they employed

the Taguchi technique. The selected parameters were welding current,

arc voltage, welding speed and electrode stick. Multiple regression

model was developed to predict the quality of weld.

2.3 Conventional and Non-Conventional Machining Processes

Harish and Pradeep [60] applied the L27 (313) OA to minimize the

feed force. The selected parameters were cutting speed, feed rate and
 42

depth of cut and the interaction between the process parameters.

Experiments were repeated thrice. The S/N ratios of “lower-the–better”

type were calculated for all the 27 runs. ANOVA estimated the

contributions of various parameters. The contribution of depth of cut

was 55.15%, feed rate was 23.33% and cutting speed was 2.63%, at

95% confidence level.

Gopal et al. [61] applied the Taguchi optimization technique to

optimize the process parameters of Drill-Reamer operation. The

objective was to improve the surface finish. The L8 orthogonal array

was selected with three operating parameters. They were cutting

speed, depth of cut and depth of feed. Each parameter had two levels.

The Drill-Reamer operations were carried out for mild steel, aluminum

and cast Iron. Three replications were conducted for all the three

materials and the average response was calculated. To study the

significance and the contributions, ANOVA computations were also

performed. The results of the investigations were as follows: the

aluminum depth of cut had almost 50% influence on the surface

finish, followed by cutting speed and feed rate. For cast Iron, the

influence of both cutting speed and feed rate was relatively high. For

mild steel, the cutting speed had high influence on the surface finish.

Cha-Lieh Yang [62] applied the Taguchi method to optimize the

glass fiber cutting process. The objective was to reduce the wear of

high Carbon steel blades. The L9 (34) orthogonal array was selected

without interactions. The operating parameters were cutting speed,

cutting volume and cutting load and an error term was also
 43

considered as a parameter. Experiments were conducted as per the

OA L9 and the average wear of the cutting blade was measured by

Scanned Electron Microscope and the S/N ratio for the same had been

calculated. The contributions of the process parameters were

estimated by ANOVA. The cutting speed had an influence of 50%,

followed by cutting volume and cutting load.

Bala et al. [63] selected the Taguchi L18 OA to analyze the

experimental result of machining with respect to the surface finish.

CNC milling was employed to perform experiments for ball end mill of

diameter 10 mm. The selected operating parameters were cutting

speed, feed, depth and width of cut. No interactions were considered

between the process parameters. Along with the evaluation of surface

finish, the tool wear and tool life were also estimated. The S/N ratios

for all the objectives had been calculated. ANOVA was applied in the

investigation to find out the influence of various parameters on the

objective function. ANOVA computations indicated that speed was

more influential than any other parameter. A multiple regression

models were developed to relate the outputs and inputs and also to

predict results.

Yin-fong Tzeng et al. [64] proposed the Taguchi method to

optimize the process parameters with the objective of improving the

machining efficiency and geometrical accuracy. The machine

employed for the investigation was FEELER QM-22 CNC precision

three axis milling machine. The work was planned in two phases. In

the first phase, the machining efficiency was optimized by conducting

 44

experiments as per the L8 OA. The process parameters were milling

type, cutting speed, feed per tooth, film material, number of teeth,

rake angle and helix angle. ANOVA computations revealed that the

combined contribution of the control factors of cutting speed, number

of teeth and feed was 82.63%. The contribution of the noise factor was

only 0.328%. In the second phase, a linear regression model was

developed between the programmed dimensions and the actual

dimensions produced in the experiments of the first phase.

Soma and Swamy [65] optimized the turning operation

parameters to get the optimal surface roughness. The operating

parameters selected were speed (A), feed (B) and depth of cut (C). For

each parameter, the range was split into three levels. Based on the

number of factors and the number of levels, the L9 OA was selected.

The details of the experiments were CNC lathe, AL 6351 work material

with 75mm length and 25.3mm diameter dimensions. Using the

Minitab software, a model was developed for experimental purpose.

Ra = 1.69+0.00146 A -1.92 B +0.24 C --- --Eq. (2.1)

Pragnesh et al. [66] investigated the effect of machining factors

on both the surface finish and the power consumption. For the

investigation, the full factorial design of experiments was adopted. The

machining was performed on 6063 aluminum composite with

Titanium Carbide (TiC) reinforcement. The engine lathe and the

cutting tool machines were used. These machines contained

polycrystalline diamond insert of fine grade. The selected parameters

were cutting speed, feed rate and depth of cut. Each parameter range
 45

was split into three meaningful levels. Based on 33, 27 trails were

conducted and objective quality responses, surface roughness and

power consumed were measured. An ANOVA computation of the result

revealed the influence of various parameters on surface roughness

and power consumption.

Danial et al. [67] proposed the design of experiment method to

maximize the material removal rate (MRR) in Wire Electrical Discharge

Machining. The selected parameters were pulse time, pulse off time

and peak current. Each parameter was split into three levels.

Experiments were conducted as per the central composite design.

ANOVA computations signified peak current for MRR and the

estimated contribution was 57.65%.

Venkataramana et al. [68] optimized the machining operation

parameters to get adequate surface finish. The selected control factors

were cutting speed, feed and depth of cut - each factor with three

levels. Based on the factors and their levels, the OA L9 was selected for

conducting the experiment.

Surinder et al. [69] employed the L8 OA to evaluate the influence

of cutting parameter on the cutting performance of Unidirectional

Glass Fiber Reinforced Plastics (UD-GFRP). The selected parameters

were cutting speed (A), feed rate (B), depth of cut (C) and interactions

AxB, AxC and BxC. The contributions of various parameters were

calculated by using ANOVA. The contribution of depth of cut was

53.87%, whereas other parameters’ contributions were relatively less.

 46

Neeraj and Rajesh [70] studied the effect of various process

parameters of Wire Electric Discharge Machining, such as pulse

width, time between two pulses, maximum feed rate, voltage, short

pulse and wire mechanical tension on surface roughness, while

machining cryogenic treated D-3 material. Experiments were

conducted as per the L27 OA; and, ANOVA computations were also

calculated to know the significance and contribution of the process

parameters.

Sahil et al. [71] investigated the cutting parameters of surface

finish of EN-8 steel using CNC turning machine. In this case also, the

selected parameters were cutting speed, feed and depth of cut. The

ANOVA results revealed that the influence of cutting speed was higher

(54.74%) than other parameters.

Shanti et al. [72] adopted the L27 (313) OA to investigate the

effect of drilling operating parameters on burr height. The parameters

selected were cutting speed, feed rate and point angle. The S/N ratio

of “smaller-the-best” type was also calculated.

Irfan et al. [73] performed experimental investigation work

similar work of the Shanti Prakash et al., The authors had used

Acrylic sheet, in contrast to Prakash’s work material that was steel.

Chaudhari et al. [74] utilized Taguchi's L9 OA to analyze the

effect of cutting parameters on the MRR and surface roughness. The

selected parameters were cutting speed, feed and depth of cut.

Izzet Karakut et al. [75] studied the effects of the process

parameters on the Kerf angle. Taguchi's L16 OA was employed to

 47

conduct the experiments. The process parameters were traverse

speed, abrasive flow rate, standoff distance, water pressure and

abrasive size. ANOVA computations revealed that the percentage

contribution of traverse speed was high at about 35% and the stand

off distance was 33%.

Pai et al. [76] investigated the effects of the grinding process

parameters on the metal removal rate and the surface roughness on

surface grinding of AL-6061-SiC composite using Taguchi's Design Of

Experiments. The selected parameters were percentage of SiC, feed

and depth of cut. Experiments were conducted as per the L27 OA.

ANOVA calculations were performed to estimate the contribution of

the process parameters.

Ravinder [77] studied the effect of the process parameters on

ceramic coating by cold spraying. The selected process parameters

were gas inlet pressure, gas inlet temperature, particle diameters and

particle temperature. Experiments were conducted as per the L16 OA.

ANOVA computations were performed to estimate the contribution of

the process parameters.

Patel [78] have done investigations similar to Bala Murugan

[63], in which the material was AL 6351-T6 and the machine used was

BFW V-30 CNC vertical milling machine.

Asafa and Fadare [79] optimized the cutting parameters with the

objectives of reducing flank wear and nose wear. A model was also

developed using MATLAB neural network tool box.

 48

Marimuthu and Chandrasekaran [80] optimized the cutting

parameters of Fanuc CNC machine to machine stainless steel, with

the objective of reducing tool wear and surface roughness. The cutting

tool used was multi-layered CNMG 120408 coated with TiCN+ AL2O3

of 14 µm. The selected parameters were cutting speed, feed and depth

of cut. Experiments were conducted as per the L27 OA.

Ashok and Bidyadhar [81] conducted experimental studies on

turning using coated carbide insert. The process was optimized by

employing Taguchi’s L27 orthogonal array. The objective of the

optimization was to predict the surface roughness. The cutting

parameters used were cutting speed, feed and depth of cut. Models

required for the experimental conditions were developed by using the

response surface methodology.

Rama Rao et al. [82] optimized the process parameters of

chemical machining to machine LM6 aluminum composites. The

selected parameters were voltage, feed rate and electrolyte

concentration. Experiments were conducted as per the L9 OA. The

objective function of this investigation was to improve the MRR. The

contributions of various parameters were calculated by ANOVA. The

contribution of feed rate was 58% and the contribution of other

parameters was relatively low. An association between the outputs

and the inputs was investigated through the regression model.

Ballal et al. [83] employed the Taguchi L27 OA to study the

effects of machining parameters on surface finish, tool wear and MRR,

in the turning of cast Iron (FG260) brake drum.

 49

Kamaraj et al. [84] optimized the parameters of the machining

process to machine Martensitic Stainless Steel (AISI410). The L27 OA

was selected, based on the parameters and their levels. The

parameters were cutting speed, feed rate, depth of cut and cutting

tool. ANOVA computations were performed to estimate the significance

of the operating parameters.

Anil and Jyoti [85] applied the L9 OA to optimize the end milling

process parameters to machine mild steel. The selected process

parameters were spindle speed, feed rate, depth of cut and width of

cut. The main objective was to estimate the removal rate of material

and surface finish.

Swaraj and Bindu [86] optimized the Micro-EDM process

parameters. For this, they adopted the L18 OA and selected polarity,

speed of electrode, peak current and pulse time as the important

operating parameters.

Bharat et al. [87] optimized the process parameters of CNC

milling operation. The L25 OA was employed with machining

parameters of depth of cut, speed and feed. The optimum parameters

were selected, based on the S/N ratios obtained.

Khairi et al. [88] employed Taguchi’s L8 (27) OA to optimize the

end milling parameters with the objective of improving the surface

finish.

Mustafa et al. [89] optimized the turning parameters by

employing parameters that were decided and based on the S/N

calculations and ANOVA results.

 50

Marinkovic Velibor et al. [90] optimized the machining

parameters by employing the Taguchi technique. The work material

used for investigation was cold rolled alloy steel. The objective was to

get good surface finish. Experiments were conducted as per the L27

OA.

2.4 Other Productive and Non-Productive Processes

Kumaruddin et al. [91], in their studies, applied Taguchi’s

Design of Experiments to improve the quality characteristics

(shrinkage) of the plastic tray produced by the injection molding

process. The process parameters were injection speed, temperature,

injection pressure, holding pressure, holding time and cooling time.

The injection speed range was split into two levels and the other

factors were split into three levels. The L18 (21X37) OA with eight

columns and 18 rows was used for this study. ANOVA computations

were used to estimate the contribution of melting temperature

(52.4%), holding pressure (3.6%), holding time (0.9%) and cooling time

(6.9%).

Bastami et al. [92], in their studies, applied the Taguchi

optimization technique to maximize the compressive strength of high

strength concretes. For this work, four control factors were selected.

They were water to cement (W/C) ratio, sand ratio fin (%), Silica fume

and Silica fume ratio (%). Each factor’s range was split into three

levels and 16 experiments were conducted.

Ozturk et al. [93] optimized the seed flow evenness in the seed

drills of the fluted feed rolls. The selected parameters were flute shape,
 51

flute length and rotational speed. Each factor was split into three

levels and experiments were conducted as per the L9 OA.

Rajesh et al. [94] recommended the selection and evaluation of

suppliers based on the quality loss function. The quality loss function

can be nominal-is-best, smaller-is-best or higher-is-best, depending

on the type and on the nature of the component.

Siddesha et al. [95] investigated the effect of the process

parameters of forming process on the microstructure and mechanical

properties of corrugated sheets. The selected process parameters were

strain rate, number of passes and plate thickness. The L27 OA was

opted to study the interactions along with the main effects.

The published work of Adil and Moutawakil [96] is the result of

an experimental investigation carried out to optimize the weight of

glass bottle in manufacturing. The selected manufacturing parameters

were feeder heating temperature, ventilation time and annealing

temperature. Each parameter had three levels. Experiments were

conducted as per the L16 (215) OA and the contribution of parameters

was calculated by ANOVA computations.

The investigation work of Supriyo and Prasanta [97] deals with

the chemical deposition of Ni-P-W coating on mild steel substrate and

optimization of surface roughness. The three coating parameters,

namely concentration of nickel, reducing agent and tungsten, were

varied to obtain optimum conditions using Taguchi method.

 52

Muthu et al. [98] employed the Taguchi loss function to

compute the quality loss per a running unit of time of the injection

molding machine.

The investigation of Reddy et al. [99] deals with the experimental

verification of parameters of a solar parabolic trough in the winter

conditions and to obtain the optimum process parameters by using

the grey relation analysis. The selected parameters were reflector

material, absorber material, position of absorber tube and angle of

absorber. Experiments were conducted as per Taguchi's L9 OA.

Hasani and Hossein [100] studied the effect of different

parameters of siro-jet spun on the performance of the jet. The selected

parameters were main hole diameter, number of sub-holes, inlet and

outlet shapes, angle of sub-holes and sub-hole diameter. Experiments

were conducted as per the L9 OA.

Hosseinpour et al. [101] adopted Taguchi’s L18 OA to optimize

the laser forming. The single objective was the maximization of the

bending angle. The selected parameters were material, power, scan

velocity, beam diameter, sheet thickness, pass number and pulse

duration.

Saravana et al. [102] studied desizing of cotton fabrics using

thermophile -amylases by using Taguchi’s Design of Experiments.

The experiments were carried out with the L9 OA and the process

variables were treatment time, temperature, PH value and enzyme

concentration.
 53

Shiva and Ravi [103] optimized the direct injection single

cylinder diesel engine with respect to brake power, fuel economy and

emissions, through experimental investigations and design of

experiments. The selected parameters were compression ratio,

injection pressure, injection timing, fuel fraction and power. The

experiments were carried out as per the L16 OA.

Pilanee and Jirawate [104] employed the L9 Taguchi design to

enhance the production of white rot fungus. The selected factors were

concentration of cellobiose, peptone, L-asparagine and CuSo4, each

factor having three levels. The result of the study was that the yield

increased with the optimization of the production medium.

Panchakshari et al. [105] applied the Taguchi method to study

the effect of cryogenic parameters on the wear behavior of aluminum-

Al203 metal matrix composites. Experiments were conducted as per

the L9 OA. The selected parameters were temperature, duration of

treatment and reinforcement; and, ANOVA was also applied to

determine the contributions of each factor.

Khan et al. [106] investigated the effect of drilling parameters

namely, spindle speed, drill point angle and feed rate, on the

expansion of hole in acrylic sheet. For this, they selected the L9 OA.

Based on the S/N ratio, the optimum drilling parameters were

determined to give the minimum expansion.

Nikul et al. [107] selected Taguchi’s L27 OA to optimize the

surface finish of the machined components by the peeling operation.

The selected peeling process parameters were cutting speed, feed and
 54

depth of cut. The mean plots showed that among all the parameters,

cutting speed had the maximum impact on surface roughness.

Yogendra et al. [108] optimized the CNC drilling machine

operating parameters with the objective of improving surface finish

and MRR. The selected parameters were spindle speed, feed rate and

depth of cut. Experiments were conducted according to the L9 OA and

the ANOVA computation estimated that the contribution of feed rate

was the highest (39.3%) when compared to other parameters.

Asafa and Fadare [109] optimized the turning parameters to

machine Nigerian Steel 37.2 with uncoated carbide tool, with the

objective of minimizing nose and flank wear. The selected parameters

were cutting speed, feed rate and depth of cut.

Dyi-Cheng Chen et al. [110] applied Taguchi optimization

technique to optimize extrusion parameters. The selected factors were

semi-cone angle diameter of the die hole, friction, velocity of the ram

and temperature of the billet. The L18 OA is employed with objective of

extruding damage free products.

Rashidaee and Asghar [111] employed Taguchi’s Design of

Experiments to optimize the Interior Permanent Magnet motor

dimensions. The results were simulated and confirmed by Finite

Element Analysis.

Karthikeyan et al. [112] optimized the diesel engine parameters

for turpentine mixed diesel using the Taguchi method. The selected

parameters were blending proportion, injection timing and injection

pressure with the objective of improving the brake thermal efficiency.

 55

Prabhu and Vinayagam [113] to employed the Taguchi method

to optimize the electrical discharge machining process. The objective

of the investigation was to obtain a better machined surface. The

machining was performed on carbon nano tubes.

Randhir et al. [114] optimized the process parameters required

to forge A356 aluminum alloy. The selected parameters were forging

temperature, percent reduction and die temperature. Experiments

were conducted as per the L9 (34) OA. The objective was to improve the

hardness.

Shiva et al. [115] used Taguchi’s technique as a methodology to

improve the production of ethanol.

Salehuddin et al. [116] used the Taguchi method to optimize the

effect of halo implant variations on critical values of voltage (Vth) and

leakage current (ILeak) in 45nm P-type metal oxide semiconductor field

effect transistors.

Venkata et al. [117] optimized the carbon dioxide (CO2) molding

parameters. The objective was to achieve better knockout property or

collapsibility. The process parameters selected were Sodium Silicate,

gassing time, mixing time and percentage of coal dust. The L8 OA,

with four factors and two interactions each in two levels, was adopted

for the investigation.

Nikhil and Karunakar [118] optimized the process parameters of

investment casting by employing the Taguchi method, for casting

A713 alloy. The selected parameters were Silica sand mesh numbers,
 56

pre-heating temperature, pouring temperature and pre-heating time.

Experiments were conducted as per the L9 OA.

Senthil et al. [119] applied the L9 OA of the Taguchi technique

to optimize the control parameters of the heat pipe. In this

investigation, the selected control parameters were heat input,

inclination angle and flow rate. Each control parameter range was

split into three levels. Experiments were conducted as per the OA.

ANOVA computations were also done to estimate the contribution of

the control parameters.

Osman et al. [120] applied the L16 OA of the Taguchi technique

to optimize the control parameters of the pavement concrete. In this

investigation, the selected parameters were water to cement ratio,

gradation type, fly ash content and Silica fume content. Each

parameter range was split into four levels. Experiments were

conducted as per the OA. ANOVA computations were also done to

estimate the contribution of each control parameter.

Rangacharyulu and Lal [121] applied the L8 OA of the Taguchi

technique to optimize the process parameters of 500 million transistor

integrated circuit chip. In this investigation, the selected process

parameters were the number of metal layers, minimum feature size,

resistivity, threshold voltage, effective length, saturation drain current

and supply voltage. Each process parameter range was split into two

levels. Experiments were conducted as per the OA.

Maria et al. [122] analyzed the influence of composition and

curing conditions of polyester and epoxy concrete to improve the

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bending strength. The Taguchi technique of L16 OA was employed for

this investigation. The selected parameters were Resin type, Resin

content, charge content in Resin, sand type and curing cycle. The

selected factors were analyzed by using the ANOVA technique.

Pascal et al. [123] applied the L16 OA of the Taguchi technique to

optimize the process parameters of water pump of an automotive

combustion engine. In this investigation, the selected process

parameters were primary ring variant, normal load, surrounding,

mating ring finishing and rotational frequency. Each process

parameter range was split into two levels.

Prabir and Reeta [124] applied the L9 OA of the Taguchi

technique to optimize the process parameters of fly ash brick. The

selected process parameters were water/binder ratio, fly ash, coarse

sand and stone dust. Each process parameter range was split into

three levels. Experiments were conducted as per the OA.

Ibhadode and Dagwa [125] applied the L9 OA of the Taguchi technique

to optimize the process parameters of Asbestos friction lining material,

used for automobile disk brake pads. In this investigation, the

selected process parameters were molding pressure, molding

temperature, curing time and heat treatment time. Each process

parameter range was split into three levels. Experiments were

conducted as per the OA.

Ali et al. [126] applied the L16 OA of the Taguchi technique to

optimize the process variables of rotor pole shaped magnet used in DC

motor for industrial applications. In this investigation, the selected

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process variables were cogging torque and weighting factors. Each

process variable was split into four levels. Experiments were

conducted as per the OA..

Ismail et al. [127] applied the L9 OA of the Taguchi technique to

optimize the environmental factors of thermal comfort in automotive

parts assembly factory. In this investigation, the selected

environmental factors were luminance (lux), relative humidity (%) and

WBGT (°C). Each process variable range was split into three levels.

Palaniradja et al. [128] applied L9 OA of Taguchi technique to

optimize the process variables in gas carburizing process of SAE 8620

and AISI 3310 Steels used for automobile engineering to improve the

surface hardness. In this investigation the selected process variables

were namely, holding time, carbon potential, carburizing temperature

and quenching time. Each process variable range was split in to three

levels. Experiments were conducted as per OA.

Hsun-Heng Tsai et al. [129] applied the L18 OA of the Taguchi

technique to optimize the dynamic characteristics of a surface

acoustic wave gas sensor.

Yun-Kon et al. [130] applied the L18 OA of the Taguchi technique

to optimize the adhesion strength of Arc Ion Plating of TiAIN Films

used for the hard coating technique of cutting tools in industrial

applications, to increase the hardness of the cutting tools.

Chih Hsiang et al. [131] applied the L18 OA of the Taguchi

technique to optimize the experimental process parameters in the

preparation of Manganese Oxide electrode for the electrochemical

 59

capacitor, to increase the capacitance. In this investigation, the

selected process parameters were concentrations of Manganese

Acetate, temperature, deposition time and deposition voltage.

Gou-Jen et al. [132] applied the L25 OA of the Taguchi

technique to optimize the process parameters of the chemical

mechanical polishing process.

Akshay and Ishtiaque [133] applied L4 OA of Taguchi technique

to optimize the spinning process variables to get optimum the packing

density of textile.

Zaheri et al. [134] applied the L9 OA of the Taguchi technique to

optimize the control parameters of Uranium separation from synthetic

effluents by electrodialysis, in the nuclear industry. In this

investigation, the selected control parameters were feed concentration,

flow rate and voltage. Each control parameter range was split into

three levels. Experiments were conducted as per the OA. ANOVA was

used to determine the factors that influence the separation

percentage.

Cosmin et al. [135] applied the L8 OA of the Taguchi technique

to optimize the process parameters in the Laser Processing of

Polycarbonate Cogwheels.

Eddie et al. [136] applied the L27 OA of the Taguchi technique to

optimize the process parameters of the compressor system to reduce

the length of time needed for its steady state.

Prakash et al. [137] resorted to the L9 OA of the Taguchi

technique to optimize the operating parameters of a four stroke single

 60

cylinder, Karanja oil-operated Kirloskar AV1 D.I. engine. The objective

of the investigation work was to reduce the emission level and

increase the performance.

The literature review concludes that several researchers

conducted experiments on optimization of manufacturing processes,

like casting, machining, powder metallurgy and various welding

methods for different objective functions. However optimization of

SMAW for producing leak-free joints is not found.

SMAW is versatile process and used extensively by the small

and large scale industry, hence enhancement of SMAW process is

both necessary and essential. Presently, industries are finding difficult

to control the parameters of SMAW process, since it is very core type

(not sophisticated) welding process, compare to other high end

welding processes like orbital welding and robot welding process. Due

to this, production of leak - free pipe joints under regular and normal

shop floor condition is very difficult.

Therefore optimization of SMAW process parameters to weld

pipes with the objective of producing leak-free joints has become

synergy of the research work. The gap found in literature survey is

that, economical and versatile SMAW process can be exploited and

explored to meet high quality and quantity requirements of new era

industries, in particular small-scale industries by optimizing the

process parameters. The present work objective is to replace

sophisticated and costly welding process by most economical SMAW.