Abstract: The plastic industry plays very important role in the
economy of any country. It is generally among the leading share of
the economy of the country. Since metals and their alloys are very
rarely available on the earth. Therefore, to produce plastic products
and components, which finds application in many industrial as well
as household consumer products is beneficial. Since 50% plastic
products are manufactured by injection moulding process. For
production of better quality product, we have to control quality
characteristics and performance of the product. The process
parameters plays a significant role in production of plastic, hence the
control of process parameter is essential. In this paper the effect of
the parameters selection on injection moulding process has been
described. It is to define suitable parameters in producing plastic
product. Selecting the process parameter by trial and error is neither
desirable nor acceptable, as it is often tends to increase the cost and
time. Hence, optimization of processing parameter of injection
moulding process is essential. The experiments were designed with
Taguchi’s orthogonal array to achieve the result with least number of
experiments. Plastic material polypropylene is studied. Tensile
strength test of material is done on universal testing machine, which
is produced by injection moulding machine. By using Taguchi
technique with the help of MiniTab-14 software the best value of
injection pressure, melt temperature, packing pressure and packing
time is obtained. We found that process parameter packing pressure
contribute more in production of good tensile plastic product.
Abstract: In this study, a multi objective optimization for end
milling of Al 6061 alloy has been presented to provide better
surface quality and higher Material Removal Rate (MRR). The input
parameters considered for the analysis are spindle speed, depth of cut
and feed. The experiments were planned as per Taguchis design of
experiment, with L27 orthogonal array. The Grey Relational Analysis
(GRA) has been used for transforming multiple quality responses
into a single response and the weights of the each performance
characteristics are determined by employing the Principal Component
Analysis (PCA), so that their relative importance can be properly and
objectively described. The results reveal that Taguchi based G-PCA
can effectively acquire the optimal combination of cutting parameters.
Abstract: The operating control parameters of injection
flushing type of electrical discharge machining process on stainless
steel 304 workpiece with copper tools are being optimized
according to its individual machining characteristic i.e. material
removal rate (MRR). Lower MRR during EDM machining process
may decrease its- machining productivity. Hence, the quality
characteristic for MRR is set to higher-the-better to achieve the
optimum machining productivity. Taguchi method has been used
for the construction, layout and analysis of the experiment for each
of the machining characteristic for the MRR. The use of Taguchi
method in the experiment saves a lot of time and cost of preparing
and machining the experiment samples. Therefore, an L18
Orthogonal array which was the fundamental component in the
statistical design of experiments has been used to plan the
experiments and Analysis of Variance (ANOVA) is used to
determine the optimum machining parameters for this machining
characteristic. The control parameters selected for this
optimization experiments are polarity, pulse on duration, discharge
current, discharge voltage, machining depth, machining diameter
and dielectric liquid pressure. The result had shown that the higher
the discharge voltage, the higher will be the MRR.
Abstract: Ultrasonic machining (USM) is a non-traditional
machining process being widely used for commercial machining of
brittle and fragile materials such as glass, ceramics and
semiconductor materials. However, USM could be a viable
alternative for machining a tough material such as titanium; and this
aspect needs to be explored through experimental research. This
investigation is focused on exploring the use of ultrasonic machining
for commercial machining of pure titanium (ASTM Grade-I) and
evaluation of tool wear rate (TWR) under controlled experimental
conditions. The optimal settings of parameters are determined
through experiments planned, conducted and analyzed using Taguchi
method. In all, the paper focuses on parametric optimization of
ultrasonic machining of pure titanium metal with TWR as response,
and validation of the optimized value of TWR by conducting
confirmatory experiments.
Abstract: The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.