This Excel Sheet is created by Dr. P. R.

Apte, IIT Bombay, Powai, Mumbai-400 076, India

e-mail: apte@ee.iitb.ac.in , web-page : http://www.ee.iitb.ac.in/~apte

Title of the problem Optimization of the EDM process

Write a BRIEF Intro to the problem MRR to be maximized

EW% to be minimized

Team members

Duration start date 27-Sep-06

Date today 21-Jun-24

Last Modified on 27-Oct-2009

password info for P. R. Apte: L9**** ==> L9 :- upto 4 control factors with 3 levels each
0 076, India
e

YOU MAY OVER-WRITE ON

THE 'orange' TEXT

IN ALL THE SHEETS

 This Excel Sheet is created by Dr. P. R. Apte, IIT Bombay, Powai, Mumbai-400 076, India
e-mail: apte@ee.iitb.ac.in , web-page : http://www.ee.iitb.ac.in/~apte

USERNAME
START DATE
27-Sep-06 TYPE
THE DATE HERE

STEP 1: Identify Main Function, failure mode and side effects EDM machining process optimization

STEP 2: Identify Noise factors, testing conditions (to capture the The hardness of the material and Bath temperatur
effects of noise) NoIsE factors. Effect of these will be captured by u
experiment (Hard/Soft + High/Low temperatures)

STEP 3: Identify Quality Characteristics and Objective Function The objective of the Taguchi experimentation is to
the Electrode Wear %.

STEP 4: Identify Control Factors and their Levels Control Factors are (1) Pulse-On Time, (2) Gap C
Current.
Their levels are taken as far apart as possible

STEP 5: Identify Orthogonal Array (degrees of freedom for error) L9 array is chosen
upto 4 control factors with 3 levels each are al

Interaction among the control factors can not b

Reference : "Quality Engineering using Robust Design" by

M.S. Phadke, Prentice Hall 1989, Chapter 4

Last Modified on 15-Feb-2007

Mumbai-400 076, India
b.ac.in/~apte

TODAY
21-Jun-24

rocess optimization

he material and Bath temperature are considered to be the

ect of these will be captured by using 4 samples for each
Soft + High/Low temperatures)

he Taguchi experimentation is to increase MRR and reduce

ar %.

e (1) Pulse-On Time, (2) Gap Current and (3) Bipulse

ken as far apart as possible

en
ctors with 3 levels each are allowed.

ng the control factors can not be studied,

 S-N RATIO
Smaller-the-better Nominal-the-Best Larger-the-Better Mean
QUALITY CHAR.

Material Removal Rate YES

Type Quality
Characteristic Type YES or NO
name/identifier
Repetitions in each row of expt Repetitions of confirmation
(due to NoIsE Factor expt (using the 'best'
combinations) settings)

9 5

You may overtype the

Type the number of
number of measurements for
times the 'BEST"
each experiment.
experiment (with 'best'
(due to NoIsE Factor
CF levels) is repeated
combinations)
 LEVELS
CONTROL FACTORS \ LEVELS 1 2

Pulse-On Time P1 P2
Gap Current G1 G2
Bi-Pulse Current B1 B2
empty S1 S2

"empty", "-" are reserved

for indicatiing 'blank' columns

NoIsE FACTORS \ LEVELS NoIsE Level 1 NoIsE Level 2

U NoIsE FACTOR 1 U1 U2
V NoIsE FACTOR 2 V1 V2

W NoIsE FACTOR 3 W1 W2

X NoIsE FACTOR 4 X1 X2

Go to a cell, delete contents (using 'delete' key) and write the

Control Factor names (necessary) & Level names (optional)
 3

P3
G3
B3
S3

NUMBER OF
NoIsE Level 3
LEVELS
U3 3 Type 2 or 3
V3 3

W3 3

X3 3

OKAY
key) and write the WHICH
OUTER-
names (optional) ARRAY IS
REQUIRED = L9
 L9 Array

Control Factors
Expt. No. A B C D
1 1 1 1 1

2 1 2 2 2
L9 Array is
3 1 3 3 3 always the same
4 2 1 2 3

5 2 2 3 1
and
6 2 3 1 2
Hence no need
7 3 1 3 2 to change this -
8 3 2 1 3 EVER
9 3 3 2 1

total number of expts = 9

REPETITIONS FOR EACH LEVEL = 3
L9 ARRAY
CHOSEN FACTORIAL OR
ORTHOGONAL
ARRAY==>L9

REPETITIONS
NUMBER OF
9
MEASUREMENTS
NoIsE FACTOR names

U NoIsE FACTOR 1
V NoIsE FACTOR 2
W NoIsE FACTOR 3
X NoIsE FACTOR 4

Control Factors Assigned to columns

Bi-Pulse
Expt. No. Pulse-On Time Gap Current
Current
empty

1 P1 G1 B1 S1
2 P1 G2 B2 S2
3 P1 G3 B3 S3

4 P2 G1 B2 S3
5 P2 G2 B3 S1
6 P2 G3 B1 S2

7 P3 G1 B3 S2
8 P3 G2 B1 S3

9 P3 G3 B2 S1

CHOSEN
FACTORIAL OR
ORTHOGONAL
ARRAY L9

F2 EXPT NO.
A
B
C
D

F3 EXPT NO.
A
B
 C
D

F4 EXPT NO.
A
B
C
D

F6 EXPT NO.
A
B
C
D

F8 EXPT NO.
A
B
C
D

F12 EXPT NO.

A
B
C
D

F16 EXPT NO.

A
B
C
D

L4 EXPT NO.
A
B
C
D

L8 EXPT NO.
A
B
C
D

L9 EXPT NO.
A
B
C
D
NoIsE Factor combinations used as repetitions for each (row of) experiment

L4 / F4 F6 F8 / L8 L9 L
F16

1 2 3 4 5 6 7 8 9

U1 U2 U3 U1 U2 U3 U1 U2 U3
V1 V2 V3 V2 V3 V1 V3 V1 V2
W1 W2 W3 W3 W1 W2 W2 W3 W1
X X X X X X X X X

meas meas meas meas meas meas meas meas meas

#1 #2 #3 #4 #5 #6 #7 #8 #9

2.86E+02 2.88E+02 2.74E+02 2.74E+02 2.86E+02 2.88E+02 2.74E+02 2.74E+02 2.86E+02

3.76E+02 3.75E+02 3.64E+02 3.66E+02 3.76E+02 3.75E+02 3.64E+02 3.66E+02 3.76E+02

5.41E+02 5.40E+02 5.31E+02 5.29E+02 5.41E+02 5.40E+02 5.31E+02 5.29E+02 5.41E+02

3.27E+02 3.26E+02 3.21E+02 3.18E+02 3.27E+02 3.26E+02 3.21E+02 3.18E+02 3.27E+02

4.05E+02 4.07E+02 3.98E+02 3.94E+02 4.05E+02 4.07E+02 3.98E+02 3.94E+02 4.05E+02

5.31E+02 5.29E+02 5.22E+02 5.24E+02 5.31E+02 5.29E+02 5.22E+02 5.24E+02 5.31E+02

3.37E+02 3.35E+02 3.28E+02 3.26E+02 3.37E+02 3.35E+02 3.28E+02 3.26E+02 3.37E+02

3.08E+02 3.10E+02 3.04E+02 3.02E+02 3.08E+02 3.10E+02 3.04E+02 3.02E+02 3.08E+02

5.54E+02 5.51E+02 5.40E+02 5.38E+02 5.54E+02 5.51E+02 5.40E+02 5.38E+02 5.54E+02

DATA COPIED FROM THE COPY DATA SHEET

1 2 3 4 5 6 7 8 9 10
1 2

1 2 3 4 5 6 7 8 9 10
1 2 3
1 2 3 4 5 6 7 8 9 10
1 1 2 2
1 2 1 2

1 2 3 4 5 6 7 8 9 10
1 1 1 2 2 2
1 2 3 1 2 3

1 2 3 4 5 6 7 8 9 10
1 1 1 1 2 2 2 2
1 1 2 2 1 1 2 2
1 2 1 2 1 2 1 2

1 2 3 4 5 6 7 8 9 10
1 1 1 1 1 1 2 2 2 2
1 1 1 2 2 2 1 1 1 2
1 2 3 1 2 3 1 2 3 1

1 2 3 4 5 6 7 8 9 10
1 1 1 1 1 1 1 1 2 2
1 1 1 1 2 2 2 2 1 1
1 1 2 2 1 1 2 2 1 1
1 2 1 2 1 2 1 2 1 2

1 2 3 4 5 6 7 8 9 10
1 1 2 2
1 2 1 2
1 2 2 1

1 2 3 4 5 6 7 8 9 10
1 1 1 1 2 2 2 2
1 1 2 2 1 1 2 2
1 2 1 2 1 2 1 2
1 2 1 2 2 1 2 1

1 2 3 4 5 6 7 8 9 10
1 1 1 2 2 2 3 3 3
1 2 3 1 2 3 1 2 3
1 2 3 2 3 1 3 1 2
1 2 3 3 1 2 2 3 1
ent

L12

No need to feed
anything here.

All 'text' is
linked to entries
in the sheet
"Control Factors
and Levels"

OPY DATA SHEET

11 12 13 14 15 16

11 12 13 14 15 16
11 12 13 14 15 16

11 12 13 14 15 16

11 12 13 14 15 16

11 12 13 14 15 16
2 2
2 2
2 3

11 12 13 14 15 16
2 2 2 2 2 2
1 1 2 2 2 2
2 2 1 1 2 2
1 2 1 2 1 2

11 12 13 14 15 16

11 12 13 14 15 16

11 12 13 14 15 16
 Repetitions or
Expt. No. Measurements for each 1 2 3 4 5 6 7 8
expt.

1 2.86E+02 2.88E+02 2.74E+02 2.74E+02 2.86E+02 2.88E+02 2.74E+02 2.74E+02

2 3.76E+02 3.75E+02 3.64E+02 3.66E+02 3.76E+02 3.75E+02 3.64E+02 3.66E+02

3 5.41E+02 5.40E+02 5.31E+02 5.29E+02 5.41E+02 5.40E+02 5.31E+02 5.29E+02

4 3.27E+02 3.26E+02 3.21E+02 3.18E+02 3.27E+02 3.26E+02 3.21E+02 3.18E+02

5 4.05E+02 4.07E+02 3.98E+02 3.94E+02 4.05E+02 4.07E+02 3.98E+02 3.94E+02

6 5.31E+02 5.29E+02 5.22E+02 5.24E+02 5.31E+02 5.29E+02 5.22E+02 5.24E+02

7 3.37E+02 3.35E+02 3.28E+02 3.26E+02 3.37E+02 3.35E+02 3.28E+02 3.26E+02

8 3.08E+02 3.10E+02 3.04E+02 3.02E+02 3.08E+02 3.10E+02 3.04E+02 3.02E+02

9 5.54E+02 5.51E+02 5.40E+02 5.38E+02 5.54E+02 5.51E+02 5.40E+02 5.38E+02

Feed the data in these You can have upto 16

rows and columns measurements per expt

2 NF with
2-levels each =
3 NF with
How to use NoIsE Factors for 2-levels each =
generating
repetitions for each expt
How to use NoIsE Factors for
generating
1 NF with 2-levels
repetitions for each expt 1 NF with 3-levels=
2-4 NF with
3-levels each =
 9 10 11 12 13 14 15 16

2.86E+02 2.88E+02 2.74E+02 2.74E+02

3.76E+02 3.75E+02 3.64E+02 3.66E+02

5.41E+02 5.40E+02 5.31E+02 5.29E+02

3.27E+02 3.26E+02 3.21E+02 3.18E+02

4.05E+02 4.07E+02 3.98E+02 3.94E+02

5.31E+02 5.29E+02 5.22E+02 5.24E+02

3.37E+02 3.35E+02 3.28E+02 3.26E+02

3.08E+02 3.10E+02 3.04E+02 3.02E+02

5.54E+02 5.51E+02 5.40E+02 5.38E+02

have upto 16 Blanks will not affect the results

ents per expt of mean, Variance and SN Ratio

meas.

factorial
4
L4 Orthogonal
4 Array
 factorial
6
L9 Orthogonal
9 Array
 Repetitions or
Expt. No. Measurements for each 1 2 3 4 5 6 7
expt.

1 2.86E+02 2.88E+02 2.74E+02 2.74E+02 2.86E+02 2.88E+02 2.74E+02

2 3.76E+02 3.75E+02 3.64E+02 3.66E+02 3.76E+02 3.75E+02 3.64E+02

3 5.41E+02 5.40E+02 5.31E+02 5.29E+02 5.41E+02 5.40E+02 5.31E+02

4 3.27E+02 3.26E+02 3.21E+02 3.18E+02 3.27E+02 3.26E+02 3.21E+02

5 4.05E+02 4.07E+02 3.98E+02 3.94E+02 4.05E+02 4.07E+02 3.98E+02

6 5.31E+02 5.29E+02 5.22E+02 5.24E+02 5.31E+02 5.29E+02 5.22E+02

7 3.37E+02 3.35E+02 3.28E+02 3.26E+02 3.37E+02 3.35E+02 3.28E+02

8 3.08E+02 3.10E+02 3.04E+02 3.02E+02 3.08E+02 3.10E+02 3.04E+02

9 5.54E+02 5.51E+02 5.40E+02 5.38E+02 5.54E+02 5.51E+02 5.40E+02

The data has been brought You can have upto

from previous sheet and 16 measurements
this sheet is protected per expt
 Mean Sum of
SN Ratio (Larger-
8 9 10 11 12 13 14 15 16 Squares of
the-Better)
reciprocals

2.74E+02 2.86E+02 1.27E-05 48.97

3.66E+02 3.76E+02 7.27E-06 51.38
5.29E+02 5.41E+02 3.48E-06 54.58
3.18E+02 3.27E+02 9.56E-06 50.19
3.94E+02 4.05E+02 6.21E-06 52.07
5.24E+02 5.31E+02 3.60E-06 54.44
3.26E+02 3.37E+02 9.07E-06 50.42
3.02E+02 3.08E+02 1.07E-05 49.72
5.38E+02 5.54E+02 3.35E-06 54.75

can have upto Blanks will not affect the S/N Ratio for Larger-the-better
measurements results of mean, Variance
per expt and SN Ratio
 Main Effects
Column #1
Expt. No. Pulse-On Time
SN Ratio (Larger-the-Better) OV-Mean P1 P2 P3
1 48.97 48.97
2 51.38 51.38
3 54.58 54.58
4 50.19 50.19
5 52.07 52.07
6 54.44 54.44
7 50.42 50.42
8 49.72 49.72
9 54.75 54.75

Sum 154.9 156.7 154.9

Factor-
51.84 51.64 52.23 51.63
Effects

OV-Mean 51.84 51.84

51.84 ### 51.84 ### 51.84 51.84 51.84 ###
Sum of Sq
due to
mean 24183

GrandTotal
Sum of 24224
Squares
Total SSQ 40
Main Effects
Column #2 Column #3 Column #4
Gap Current Bi-Pulse Current empty
G1 G2 G3 B1 B2 B3 S1 S2 S3
48.97 48.97 48.97
51.38 51.38 51.38
54.58 54.58 54.58
50.19 50.19 50.19
52.07 52.07 52.07
54.44 54.44 54.44
50.42 50.42 50.42
49.72 49.72 49.72
54.75 54.75 54.75

149.6 153.2 163.8 153.1 156.3 157.1 155.8 156.2 154.5

49.86 51.06 54.59 51.04 52.11 52.36 51.93 52.08 51.50

51.84 51.84 51.84

51.84 51.84 51.84 ###### 51.84 51.84 51.84 ### 51.84 51.84 51.84
 Ov-Mean

###
S/N Ratio (LARGER-the-better) in dB
YOU CAN MODIFY THE CHART -
PARTICULARLY THE Y-AXIS

Factor Effect Plot

55.00

54.00

53.00

52.00

51.00

50.00

49.00

48.00

47.00
G1

G2

G3
P1

P2

P3

B1

B2

B3

S1

S2
Control Factor Levels
THE CHART -
HE Y-AXIS

Plot
Ov-Mean
B1

B2

B3

S1

S2

S3

Levels
S/N Ratio (LARGER-the-better) in dB

Factor Effect Plot

55.00

54.00

53.00

52.00

51.00

50.00

49.00

48.00

47.00
G1

G2

G3
P1

P2

P3

B1

B2

B3

S1

S2
Control Factor Levels
 B1

Plot

Levels
B2

B3

S1

S2

S3

Ov-Mean
 LEVELS
CONTROL FACTORS \ LEVELS 1 2 3 Degrees Sum of Mean
of Squares Square
Freedo
m

Pulse-On Time 51.64 52.23 51.63 2 1 0

Gap Current 49.86 51.06 54.59 2 36 18

Bi-Pulse Current 51.04 52.11 52.36 2 3 1

empty 51.93 52.08 51.50 0 0 0

Ov-Mean 51.84 51.84 51.84

Total sum of Squares due to Factor Effects 40
Total sum of Squares = grand Total - 9*mean sq 40

Error Variance (unpooled) 2 1

Error Variance (unpooled) per degree of freedom 0.27
(Error Variance pooled)) 4 1

Error Variance per degree of freedom 0.32

Error Bar for each CF level = 2*SQRT(error var. per DF / repetition of each level) = 0.65

Prediction error variance (for 5 to 6 repititions) = sum of sq for error / neff = 0.31

95% confidence interval for pred. err = +-2*sqrt(pred err) = 1.11

OV-MEAN 51.84 51.84 51.84 51.84

Factor F before empty empty or F Error Bar
Effect pooling pooled After on each
(percent) F=<1.5 pooling CF Level

2 1 no pooled - +- 0.64 dB

90 66 no no 57 +- 0.64 dB

7 5 no no 5 +- 0.64 dB

- 0 yes yes - +- 0.64 dB

no. of unpooled CFs = 2

1/n = 1/(nexpts for mean) + (no of unpooled

CF)/(nrepeat for each level) = 0.78

nr = no of repeat 1/neff = 1/n + 1/nr

expts = 5 therefore neff = 1.02
prediction error = error variance per degree of
ffreedom/neff 0.30846966
 Type 'NEW' levels
as 1,2 or 3

L9 Control Factor
Level 1 Level 2 Level 3 SELECT
ASSIGNMENT Names
LevelName

Column 1 Pulse-On Time P1 P2 P3 1 -

Column 2 Gap Current G1 G2 G3 1 G1

Column 3 Bi-Pulse Current B1 B2 B3 1 B1

Column 4 empty S1 S2 S3 1 -

49.1
50.18 47.96

See the 'RESULTS' here 3.23E+02 to 2.50E+02

 Contribution
DOMINANT or
of SELECTed
Opt Level % Factor Effects Significant or "F" after Pooling
Level to S/N
neutral/negligible
Ratio (in dB)

- 2 0.00 neutral/negligible- -

G3 90 -1.97 D O M I N A N T 57

B3 7 -0.79 SIGNIFICANT 5

- - 0.00 neutral/negligible- -

Ov-Mean 51.84

S/N Ratio 49.07

"+-" error in dB 1.11

Material
Removal Rate
2.84E+02
Range
Center Value