CHAPTER 5

DESIGN OF EXPERIMENTS VIA TAGUCHI METHODS FOR

INCONEL 600 USING CUW ELECTRODE IN ELECTRICAL
DISCHARGE MACHINING

5.1 INTRODUCTION
The goal of the metal cutting industries is to manufacture high quality products
in a short time. INCONEL 600 has been widely applied in aerospace industry and
nuclear reactor due to its superior high temperature mechanical properties such as
resistance to oxidation and corrosion, high tensile stress and rupture stress etc, But,
machining of INCONEL 600 very difficult to machine material and produce poor
quality during machining. Electric Discharge Machining is one of the most extensively
used non-conventional material removal processes and parameters are affecting the
quality of the machined component. Optimization of machining parameters is important
to achieve high quality. Taguchi method of experimental design is one of the widely
accepted techniques for off line quality assurance of products and processes. This
method is a traditional approach for robust experimental design that seeks to obtain a
best combination set of parameters and levels with the lowest social status of cost
solution to achieve customer requirements (Kirby et al 2006; Kopac et al 2002; Korkut
et al 2004).

5.2 METHODOLOGY
Genichi Taguchi, a Japanese engineer, proposed several approaches to
experimental designs that are sometimes called Taguchi Methods. These methods utilize
two, three, and mixed level fractional factorial designs. In this work, Taguchi method, a
powerful tool in robust design was used for experimentation and analysis. L27
orthogonal array was employed to investigate the optimal settings and significant
contribution of parameters (Lin, et al 2006). Finally confirmation test was carried out at
the optimal setting of parameters recommended by the investigation. Taguchi of Nippon
Telephones and Telegraph Company, Japan has developed a method based on
orthogonal array experiments which gives much reduced variance for the experiment
with optimum settings of control parameters (Lee & Tarng 2000; Liao 2006).
Orthogonal array provides a set of well balanced experiments and S/N ratios, which are
log functions of desired output and serve as objective functions for optimization, help in
data analysis and prediction of optimum results. There are 3 S/N ratios of common
interest for optimization problems such as smaller the better, larger the better and
nominal the better. Since the objective of this work is minimization of SR, EWR and
maximization of MRR, Hardness of work surface. The S/N ratio for smaller the better
type category and larger the better category is given by the Equation 5.1 and Equation
5.2.


1 n 2 
  10 log10   yi 
 

 n i1  (5.1)

n
1 1
η = -10 log 10    2 (5.2)
 n  i 1 yij

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 as the larger-the-better type problem.

5.3. EXPERIMENTAL DETAILS

The main objective of the work is to establish a relation between pulses on,
current and pulse off on SR, EWR, MRR and Hardness. Experiments were performed
using an electric discharge machine and the work piece material is INCONEL 600
material. Kerosene was used as a dielectric fluid in this experiment and the different
parameters and levels are given in Table 5.1. The work piece dimension is 30 mm cubic
surface and copper tungsten electrode cubic is 20 mm. Hence, an experimental plan
based on Taguchi’s L27 Orthogonal array was selected.
 Table 5.1 Process parameter and levels
Input
Level 1 Level 2 Level 3
Parameters
Current (C) (amp) 5 10 15
Pulse on Time (μs) 4 5 6
Pulse off Time (μs) 5 7 9

5.4. DESIGN OF EXPERIMENTS VIA TAGUCHI METHODS FOR

INCONEL 600
The assignment of factors with their levels to columns of OA and the row
number represented by their trial number are given in Table 5.2. Based on Taguchi’s L27
OA, EDM experiments were conducted on INCONEL 600 alloy. The experimental
results such as SR, MRR, Hardness and TWR were collected for each trial and it is
shown in Table 5.3 to Table 5.6. S/N ratios were calculated for all the responses and
The S/N ratios for SR, MRR, Hardness and TWR were collected for each trial and it is
shown in Table 5.7 to Table 5.10. Since the objective of this work was the minimization
of SR, EWR and maximization of MRR, Hardness, The S/N ratio for smaller the better
type category and the better category is given by the Equation 5.1 and Equation 5.2.

Table 5.2 Assignment of the factors with levels to columns of the OA

Trial C Pon Poff
1 1 1 1
2 1 1 2
3 1 1 3
4 1 2 1
5 1 2 2
6 1 2 3
7 1 3 1
8 1 3 2
9 1 3 3
 10 2 1 1
11 2 1 2
12 2 1 3
13 2 2 1
14 2 2 2
15 2 2 3
16 2 3 1
17 2 3 2
18 2 3 3
19 3 1 1
20 3 1 2
21 3 1 3
22 3 2 1
23 3 2 2
24 3 2 3
25 3 3 1
26 3 3 2
27 3 3 3

The optimal setting levels for each factor resulting from S/N ratios for SR,
EWR, MRR, and Harness were shown in Table 5.11, Table 5.12, Table 5.13 and Table
5.14. The main effect plot for S/N ratio of SR, EWR, MRR, and Harness are shown in
Figure 5.1, Figure 5.2, Figure 5.3 and Figure 5.4. The interaction plot for S/N ratio of
SR, EWR, MRR, and Harness are shown in Figure 5.5, Figure 5.6, Figure 5.7 and
Figure 5.8.
 Table 5.3 Experimental results for SR of INCONEL 600 Alloy

C P on P off SR

5 4 5 3.251
5 4 7 3.224
5 4 9 2.982
5 5 5 3.728
5 5 7 3.466
5 5 9 4.761
5 6 5 3.527
5 6 7 5.019
5 6 9 4.363
10 4 5 3.172
10 4 7 3.528
10 4 9 4.237
10 5 5 2.256
10 5 7 5.089
10 5 9 2.748
10 6 5 6.712
10 6 7 6.683
10 6 9 5.286
15 4 5 4.266
15 4 7 5.142
15 4 9 4.11
15 5 5 2.367
15 5 7 1.355
15 5 9 6.101
15 6 5 6.223
15 6 7 5.887
15 6 9 6.634
 Table 5.4 Experimental results for EWR of INCONEL 600 Alloy

C P on P off EWR

5 4 5 0.1766
5 4 7 0.07316
5 4 9 0.02644
5 5 5 0.0864
5 5 7 0.0702
5 5 9 0.1204
5 6 5 0.2733
5 6 7 0.025
5 6 9 0.1573
10 4 5 0.0304
10 4 7 0.0271
10 4 9 0.0293
10 5 5 0.51073
10 5 7 0.04013
10 5 9 0.03901
10 6 5 0.5618
10 6 7 0.3511
10 6 9 0.2366
15 4 5 0.10304
15 4 7 0.0642
15 4 9 0.0042
15 5 5 0.3277
15 5 7 0.41396
15 5 9 0.0535
15 6 5 0.91292
15 6 7 0.4322
15 6 9 0.2593
 Table 5.5 Experimental results for MRR of INCONEL 600 Alloy

C P on P off MRR

5 4 5 8.3994
5 4 7 5.0408
5 4 9 3.7116
5 5 5 8.1132
5 5 7 8.2645
5 5 9 7.1401
5 6 5 15.6674
5 6 7 14.5612
5 6 9 12.76
10 4 5 4.6907
10 4 7 4.1536
10 4 9 5.277
10 5 5 26.7254
10 5 7 5.296
10 5 9 4.9193
10 6 5 48.3079
10 6 7 40.6583
10 6 9 32.9336
15 4 5 11.8518
15 4 7 8.3825
15 4 9 4.2705
15 5 5 28.1878
15 5 7 34.1764
15 5 9 10.4196
15 6 5 43.9501
15 6 7 48.043
15 6 9 51.04
 Table 5.6 Experimental results for hardness of INCONEL 600 Alloy

C P on P off H

5 4 5 35
5 4 7 36.5
5 4 9 33
5 5 5 36
5 5 7 33.5
5 5 9 34.5
5 6 5 34
5 6 7 34.2
5 6 9 34.5
10 4 5 35
10 4 7 39.5
10 4 9 39
10 5 5 37.5
10 5 7 39
10 5 9 33.5
10 6 5 37.5
10 6 7 38
10 6 9 38.2
15 4 5 36
15 4 7 32.5
15 4 9 40
15 5 5 39.5
15 5 7 34.7
15 5 9 33.5
15 6 5 33
15 6 7 35.5
15 6 9 36
 Table 5.7 S/N Ratio for SR of INCONEL 600 Alloy

C P on P off S/N for SR

5 4 5 -10.24
5 4 7 -10.17
5 4 9 -9.49
5 5 5 -11.43
5 5 7 -10.80
5 5 9 -13.55
5 6 5 -10.95
5 6 7 -14.01
5 6 9 -12.80
10 4 5 -10.03
10 4 7 -10.95
10 4 9 -12.54
10 5 5 -7.07
10 5 7 -14.13
10 5 9 -8.78
10 6 5 -16.54
10 6 7 -16.50
10 6 9 -14.46
15 4 5 -12.60
15 4 7 -14.22
15 4 9 -12.28
15 5 5 -7.48
15 5 7 -2.64
15 5 9 -15.71
15 6 5 -15.88
15 6 7 -15.40
15 6 9 -16.44
 Table 5.8 S/N Ratio for EWR of INCONEL 600 Alloy

C P on P off S/N for EWR

5 4 5 15.06
5 4 7 22.71
5 4 9 31.55
5 5 5 21.27
5 5 7 23.07
5 5 9 18.39
5 6 5 11.27
5 6 7 32.04
5 6 9 16.07
10 4 5 30.34
10 4 7 31.34
10 4 9 30.66
10 5 5 14.16
10 5 7 27.93
10 5 9 28.18
10 6 5 5.01
10 6 7 9.09
10 6 9 12.52
15 4 5 19.74
15 4 7 23.85
15 4 9 47.54
15 5 5 9.69
15 5 7 7.66
15 5 9 25.43
15 6 5 0.79
15 6 7 7.29
15 6 9 11.72
 Table 5.9 S/N Ratio for MRR of INCONEL 600 Alloy

C P on P off S/N for MRR

5 4 5 18.48
5 4 7 14.05
5 4 9 11.39
5 5 5 18.18
5 5 7 18.34
5 5 9 17.07
5 6 5 23.90
5 6 7 23.26
5 6 9 22.12
10 4 5 13.42
10 4 7 12.37
10 4 9 14.45
10 5 5 28.54
10 5 7 14.48
10 5 9 13.84
10 6 5 33.68
10 6 7 32.18
10 6 9 30.35
15 4 5 21.48
15 4 7 18.47
15 4 9 12.61
15 5 5 29.00
15 5 7 30.67
15 5 9 20.36
15 6 5 32.86
15 6 7 33.63
15 6 9 34.16
 Table 5.10 S/N Ratio for hardness of INCONEL 600 Alloy

C P on P off S/N for H

5 4 5 30.88
5 4 7 31.25
5 4 9 30.37
5 5 5 31.13
5 5 7 30.50
5 5 9 30.76
5 6 5 30.63
5 6 7 30.68
5 6 9 30.76
10 4 5 30.88
10 4 7 31.93
10 4 9 31.82
10 5 5 31.48
10 5 7 31.82
10 5 9 30.50
10 6 5 31.48
10 6 7 31.60
10 6 9 31.64
15 4 5 31.13
15 4 7 30.24
15 4 9 32.04
15 5 5 31.93
15 5 7 30.81
15 5 9 30.50
15 6 5 30.37
15 6 7 31.00
15 6 9 31.13
 Table 5.11 Response Table for S/N ratios of SR

Levels C P on P off
1 -11.49 -11.39 -11.36
2 -12.33 -10.18 -12.09
3 -12.52 -14.77 -12.89
Delta 1.02 4.60 1.54
Rank 3 1 2

Table 5.12 Response Table for S/N ratios of EWR

Levels C P on P off
1 21.27042 28.08883 11.00065
2 17.87872 16.38422 20.55423
3 17.07889 11.75499 24.67315
Delta 4.19 16.33 13.67
Rank 3 1 2

Table 5.13 Response table for S/N ratios of MRR

Levels C P on P off
1 18.53437 15.1911 24.39427
2 21.47918 17.67312 21.94037
3 25.91506 19.7411 19.59397
Delta 7.38 14.38 4.80
Rank 2 1 3
 Table 5.14 Response table for S/N ratios of Hardness

Level C P on P off
1 30.77 31.17 31.10
2 31.46 31.05 31.09
3 31.02 31.03 31.06
Delta 0.69 0.14 0.04
Rank 1 2 3

The Taguchi analysis for SR is given Table 5.11; it clearly shows the optimal
setting parameters for minimization of SR is current set to as 5A, pulse on set as 5µs,
pulse off set as 5µs. The Taguchi analysis for EWR is given Table 5.12; it clearly shows
the optimal setting parameters for minimization of EWR is current set to as 5A, pulse on
set as 4µs, pulse off set as 9µs. The Taguchi analysis for MRR is given Table 5.13; it
clearly shows the optimal setting parameters for maximization of MRR is current set to
as 15A, pulse on set as 6µs, pulse off set as 5µs. The Taguchi analysis for hardness is
given Table 5.14 it clearly shows the optimal setting parameters for maximization of
hardness is current set to as 10 A, pulse on set as 3 µs, pulse off set as 5µs.

Main Effects Plot (data means) for SN ratios

A B
-10

-12
Mean of SN ratios

-14

1 2 3 1 2 3
C
-10

-12

-14

1 2 3
Signal-to-noise: Smaller is better

Figure 5.1 Main effect plots for SR of INCONEL 600

 Main Effects Plot (data means) for SN ratios
A B
30

25

20

Mean of SN ratios 15

10
1 2 3 1 2 3
C
30

25

20

15

10
1 2 3
Signal-to-noise: Smaller is better

Figure 5.2 Main effect plot for EWR of INCONEL 600

Main Effects Plot (data means) for SN ratios

A B
30

25

20
Mean of SN ratios

15
1 2 3 1 2 3
C
30

25

20

15
1 2 3
Signal-to-noise: Larger is better

Figure 5.3 Main effect plot for MRR of INCONEL 600

 Main Effects Plot (data means) for SN ratios
A B

31.4

31.2

31.0

Mean of SN ratios
30.8
1 2 3 1 2 3
C

31.4

31.2

31.0

30.8

1 2 3
Signal-to-noise: Larger is better

Figure 5.4 Main effect plot for hardness of INCONEL 600

Interaction Plot (data means) for SN ratios

1 2 3

A
-10.0 1
2
-12.5 A 3

-15.0

B
-10.0 1
2
B -12.5 3

-15.0

C
-10.0 1
2
-12.5 C 3

-15.0

1 2 3 1 2 3

Signal-to-noise: Smaller is better

Figure 5.5 Interaction plot for SR of INCONEL 600

 Interaction Plot (data means) for SN ratios
1 2 3

A
30 1
2
20 A 3

10

B
30 1
2
B 20 3

10

C
30 1
2
20 C 3

10

1 2 3 1 2 3

Signal-to-noise: Smaller is better

Figure 5.6 Interaction plot for EWR of INCONEL 600

Interaction Plot (data means) for SN ratios

1 2 3

A
30
1
2
20 A 3

10
B
30
1
2
B 20 3

10
C
30
1
2
20 C 3

10
1 2 3 1 2 3

Signal-to-noise: Larger is better

Figure 5.7 Interaction plot for MRR of INCONEL 600

 Interaction Plot (data means) for SN ratios
1 2 3

A
31.5 1
2
A 3
31.0

30.5
B
31.5 1
2
B 3
31.0

30.5
C
31.5 1
2
C 3
31.0

30.5
1 2 3 1 2 3
 Signal-to-noise: Larger is better

Figure 5.8 Interaction plot for hardness of INCONEL 600

5.5. CONCLUSION
Experimental works were carried out for optimal setting of machining
parameters in EDM process on INCONEL 600 alloy. The following conclusions were
drawn.

 The Taguchi technique is the best technique for solving single response problem;
employed for EDM process parameter optimization with the objective of
minimization of the SR, EWR and maximization of MRR, hardness in EDM for
machining INCONEL 600.
 Optimal setting parameter for minimization of the surface roughness on
INCONEL 600 in EDM is current set at 5A, pulse on set at 4µs, pulse off set at
9µs. Optimal setting parameters for minimization of EWR is current set as 5A, pulse
on set as 4µs, pulse off set as 9µs. Optimal setting parameter for
maximization of MRR is current set to as 15A, pulse on set as 6µs, pulse off set as
5µs. Optimal setting parameter for maximization of hardness is current set to as 10A,
pulse on set as 3 µs, pulse off set as 5µs.