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Multi Response Optimization of Machining Parameters of Drilling Al/Sic Metal Matrix Composite Using Grey Relational Analysis in The Taguchi Method
Multi Response Optimization of Machining Parameters of Drilling Al/Sic Metal Matrix Composite Using Grey Relational Analysis in The Taguchi Method
DOI 10.1007/s00170-007-0981-4
ORIGINAL ARTICLE
Received: 12 December 2006 / Accepted: 12 February 2007 / Published online: 10 March 2007
# Springer-Verlag London Limited 2007
tigated the tool life, surface roughness and burr formation cutting point angles (90, 115 and 140 degrees), coated by TiN
in high speed drilling of stainless steel using TiN-coated are used throughout the experimental work.
carbide drill. Mohan et al. [11] studied the influence of The average surface roughness (Ra), cutting force (Fc)
process parameters on cutting force and torque during and torque (T) are considered as responses for this study. The
drilling of glass-fiber polyester reinforced composite using surface roughness is measured at three positions spaced at
Taguchi technique with the objective of minimization of 120° intervals around the hole circumference. The surface
cutting force and torque. Tosun [12] used the grey relational roughness of each hole is taken as the mean of three
analysis for the determination of optimal drilling parameters circumferential readings. The cutting force and torque for
with the objective of minimization of surface roughness and each trial is measured by using strain gauge dynamometer.
burr height. Lin et al. [13] used the grey relational analysis
method for optimization of the EDM process. Most of the 2.2 Plan of investigation
applications of Taguchi method concentrate on the optimi-
zation of single response problems [15]. The factors and their levels considered in this study are
The grey relational analysis based on grey system theory shown in Table 1. Experiments are conducted with three
can be used for solving the complicated interrelationships factors each at three levels and hence a three level
among the multi responses [14, 15]. A gray relational grade orthogonal array (OA) is chosen. Degrees of freedom
is obtained to evaluate the multiple responses. As a result, (Dof) required for the design are six. The OA, which
optimization of the multiple responses can be converted satisfies the required Dof is L9. The experiments are
into optimization of a single relational grade. In short, there conducted using L9 OA and the response values obtained
is an ample scope of applying the proposed methodology of are given in Table 2.
grey relational analysis and Taguchi method with the
multiple responses for the optimization of drilling param-
eters of Al/SiC MMC using the economic tool of TiN- 3 Optimization steps using grey relational analysis
coated HSS twist drill.
In the present study, experimental details using the Step 1 Calculate S/N ratio for the corresponding responses
Taguchi method of parameter design have been employed using the following formula.
for optimizing multiple performance characteristics such as
i Larger - the - better
surface roughness, cutting force and torque for drilling of
X
Al/SiC-MMC. Grey relational analysis has been considered 1 n 1
S=N ratio ðηÞ ¼ 10 log10 ð1Þ
for optimization of multiple response characteristics. Final- n i¼1 y2ij
ly analysis of variance (ANOVA) and confirmation test
have been conducted to validate the test result. where n=number of replications yij =observed response
value where i=1, 2, ....n; j=1, 2...k
This is applied for problem where maximization of the
quality characteristic of interest is sought. This is referred
2 Experimental works as the larger-the-better type problem.
Table 2 L9 Orthogonal array with factors and responses Normalization is a transformation performed on a single
Trial No. V F PA Responses data input to distribute the data evenly and scale it into an
acceptable range for further analysis.
Ra in μm Fc in N T in Nm
Step 2 yij is normalized as Zij (0≤Zij ≤1) by the following
1 1 1 1 7.83 107.87 0.88
2 1 2 2 4.01 254.96 2.06 formula to avoid the effect of adopting different units and to
3 1 3 3 2.22 470.67 2.26 reduce the variability. It is necessary to normalize the
4 2 1 2 6.70 186.31 1.96 original data before analyzing them with the grey relation
5 2 2 3 5.80 539.33 1.28 theory or any other methodologies. An appropriate value is
6 2 3 1 6.09 1186.53 3.24 deducted from the values in the same array to make the
7 3 1 3 6.01 274.57 0.69 value of this array approximate to 1. Since the process of
8 3 2 1 8.27 1078.66 2.55
normalization affects the rank, we also analyzed the
9 3 3 2 6.20 1274.78 2.16
sensitivity of the normalization process on the sequencing
results. Thus, we recommend that the S/N ratio value be
iii Nominal - the - best adopted when normalizing data in grey relation analysis.
μ2 yij min yij ; i ¼ 1; 2; :::::n
S=N ratio ðηÞ ¼ 10 log10 ð3Þ Zij ¼
σ2 max yij ; i ¼ 1; 2; ::::::n min yij ; i ¼ 1; 2; :::::n
ð4Þ
y1þy2þy3þ:::::::þyn
Where μ ¼ n (To be used for S/N ratio with Larger the better manner)
P
ðyiyÞ2 max yij ; i ¼ 1; 2; :::::n yij
σ2 ¼ Zij ¼
n1 max yij ; i ¼ 1; 2; ::::::n min yij ; i ¼ 1; 2; :::::n
This is called nominal-the-best type of problem where ð5Þ
one tries to minimize the mean squared error around a
(To be used for S/N ratio with smaller the better manner)
specific target value. Adjusting the mean on target by any
means renders the problem to a constrained optimization
problem.
yij Target min yij Target; i ¼ 1; 2; ::::::n
Zij ¼ ð6Þ
max yij Target; i ¼ 1; 2; :::::n min yij Target; i ¼ 1; 2; ::::::n
(To be used for S/N ratio with nominal the best manner) 6. K is the distinguishing coefficient, which is defined in
the range 0≤K≤1 (the value may adjusted based on the
Step 3 Calculate the grey relational co-efficient for the practical needs of the system)
normalized S/N ratio values.
Δ min þξΔ max Step 4 Generate the grey relational grade.
γ ðyo ðk Þ; yi ðk ÞÞ ¼ ð7Þ
Δoj ðkÞ þ ξΔ max
1X m
gj ¼ g ð8Þ
where k i¼1 ij
1. j=1,2...n; k=1,2...m, n is the number of experimental
data items and m is the number of responses. where g j is the grey relational grade for the jth experiment
2. yo(k) is the reference sequence (yo(k)=1, k=1,2...m); and k is the number of performance characteristics.
yj(k) is the specific comparison
sequence.
3. Δoj ¼ yo ðkÞ yj ðkÞ ¼ The absolute value of the Step 5 Determine the optimal factor and its level
difference between yo(k) and yj(k)
combination.
4. Δ min ¼ min minyo ðkÞ yj ðkÞ is the smallest value The higher grey relational grade implies the better
8j2i 8k
of yj(k) product quality; therefore, on the basis of grey relational
5. Δ max ¼ max maxyo ðkÞ yj ðkÞ is the largest value grade, the factor effect can be estimated and the optimal
8j2i 8k
of yj(k) level for each controllable factor can also be determined.
Int J Adv Manuf Technol (2008) 37:250–255 253
For example, to estimate the effect of factor i, we calculate the optimal level of the design parameters can be calculated
the average of grade values (AGV) for each level j, denoted as the following:
as AGVij, then the effect, Ei, is defined as: X
q
b
η ¼ ηm þ ð ηi ηm Þ
Ei ¼ max AGVij min AGVij ð9Þ
i¼1
If the factor i is controllable, the best level j*, is determined ηm ¼ Average SN ratio
by ð11Þ
η¼ Average SN ratio corresponding to ith
j ¼ maxj AGVij ð10Þ significant factor on jth level
q ¼ Number of significant factors
Step 6 Perform ANOVA for identifying the significant
factors.
The main purpose of the analysis of variance (ANOVA)
is the application of a statistical method to identify the 4 Implementation of the solution methodology
effect of individual factors. Results from ANOVA can
determine very clearly the impact of each factor on the Step 1 Calculate the S/N ratios for a given response and
process results. The Taguchi experimental method could predicted S/N ratios of the starting conditions using one of
not judge the effect of individual parameters on the entire the Eqs. (1), (2) and (3) depending upon the type of quality
process; thus, the percentage of contribution using ANOVA characteristics. The computed S/N ratios for each quality
is used to compensate for this effect. The total sum of the characteristic are shown in Table 3.
squared deviations SST is decomposed into two sources: the
sum of the squared deviations due to each process Step 2 Normalize the S/N ratio values by Eqs. (4), (5) and
parameter and the sum of the squared error. The percentage (6). The results are given in Table 3.
contribution by each of the process parameter in the total
sum of the squared deviations SST can be used to evaluate Step 3 Perform the grey relational analysis. From the data
the importance of the process-parameter change on the in Table 3, calculate the grey relational co-efficient for the
performance characteristics. Usually, the change of the normalized S/N ratio values by using Eq. (7). The value for
process parameter has a significant effect on the perfor- ξΔmax is taken as 0.5 in Eq. (7). Since all the process
mance characteristic when the F value is large. parameters are of equal weighting [12]. The results are
given in Table 4.
Step 7 Calculate the predicted optimum condition.
Once the optimal level of the design parameters has been Step 4 Next, the grey relational grade can be computed by
selected, the final step is to predict and verify the quality Eq. (8). Finally, the grades are considered for optimizing
characteristic using the optimal level of the design the multi response parameter design problem. The results
parameters. Here we have used the factor levels obtained are given in the Table 4.
by using Eqs. (9) and (10). The estimated S/N ratio using
Ra Fc T Ra Fc T
Ra Fc T