IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

A Publisher for Research Motivation........

Volume 2, Issue 10, October 2014

OPTIMIZATION OF PROCESS
PRARMETERS IN GRINDING PROCESS TO
REDUCE THE REWORK IN CASE OF
PISTON USING TAGUCHI TECHNIQUE
Praveenkumar.V.Kolhar1, Dr.R.G.Mench2
1

M Tech Student 2Professor

Dept of Industrial and Production Engg, B.V.B College of Engineering & Technology.Hubli 580 031

ABSTRACT
This paper deals with optimization of rework in grinding using Taguchi Technique. An attempt has been made to get the
optimal parameter settingon rework of grinding process. Analysis is carried using pareto analysisto identify the component in a
hydraulic cylinder to reduce the rework in an assembly line. Four parameters, namely cutting speed, feed rate, depth of cut and
material hardness were identified and the ranges of the parameters for the investigationwere determined from preliminary
experiments. Each parameter was investigated at three levels to study the non-linearity effect of the parameters. Taguchi
method based L9 orthogonal array was selected and experiments were conducted as per experiment layout plan. Based on
Signal to Noise ratio analysis, the optimal settings of the process parameters have been determined. Conformation experiments
have been performed and the average response value namely outer diameter of piston lie within the confidence interval of the
predicted optimum.

Keywords:- Rework, Grinding process, Pareto analysis, Orthogonal Array, Taguchi Technique.

1. INTRODUCTION
Grinding is a material removal and surface generation process used to shape and finish components made of metals and
other materials. The precision and surface finish obtained through grinding can be up to ten times better than with
either turning or milling.Grinding is an essential process for final machining of components requiring smooth surfaces
and precise tolerances. The grinding strongly affects the product quality and assembly process, sometimes necessitating
an additional process.The additional procedure ascompared with other machining processes, grindings,costly operation
that should be utilized under optimal conditions. Although widely used in industry, grinding remains perhaps the least
understood of all machining processes. The major operating input parameters that influence the output responseouter
diameter of piston are (i) wheel parameters: abrasives, grain size, grade, structure, binder, shape and dimension, etc.,
(ii) Work piece parameters: fracture mode, mechanical properties and chemical composition, etc., (iii) Process
parameters: work speed, depth of cut, feed rate, dressing condition, material hardness etc. (IV) machine parameters:
static and dynamic characteristics, spindle system, and table system, etc.The present paper takes thefollowing input
processes parameters namely cutting speed, feed rate, depth of cut and material hardness. The main objective of this
paper is to demonstrate howour knowledge on grinding process can be utilized to predict the grinding behavior and
achieve optimal operating processes parameters.In this paper, for reducing rework in assembly line, techniques like
Pareto-chartand DOE (Taguchi Method) are conversed in the following section.

2. LITERATURE REVIEW
M.Janardhanet al. [1] proposed that in cylindrical grinding metal removal rate and surface finish are the important
responses. The Experiments were conducted on CNC cylindrical grinding machine using EN8 material (BHN-30- 35)
and he found that the feed rate played a vital role on responses surface roughness and metal removal rate than other
process parameters. M.A. Kamelyet al. [2] have been developed a mathematical model of the surface roughness by
using response surface methodology (RSM) in grinding of AISI D2 cold work tool steels.Jae-SeobKwak [5] applied
Taguchi and response surface methodologies for geometric error in surface grinding process. The effect of grinding
parameters on the geometric error was evaluated and optimum grinding conditions for minimizing the geometric error

Volume 2, Issue 10, October 2014

Page 1

IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 2, Issue 10, October 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

were determined. A second-order response model for the geometric error was developed and the utilization of the
response surface model was evaluated with constraints of the surface roughness and the material removal rate.

3. PROBLEM STATEMENT
To optimize the process parameters in grinding process to reduce the rework in case of piston.

4. OBJECTIVES OF THE STUDY

Carried out pareto analysis to identify the component in a hydraulic cylinder to reduce the rework in an assembly
line.
Optimization of process parameters of grinding to reduce the rework of Piston in assembly line of hydraulic
cylinder.

5. PARETO ANALYSIS
It isadecision-makingtechnique that statistically
separatesalimitednumberofinputfactorsashavingthemostimpactonanoutcome,
eitherdesirableorundesirable.Paretoanalysisis prepared on the basis of the idea that80%ofaproject's
benefitcanbeachievedbydoing 20%oftheworkorconversely80%ofproblems aretraced to20%ofthecauses. Frequency of the
rework of Hydraulic cylinder components is displayed in the following table.
Table 1: PARETOAnalysis of Hydraulic Cylinder components

Fig 1: Pareto Analysis Graph

Theabove graph showstheParetoanalysis done onthebasisofreworkthat occurredintheparticularissue piston is 49.67%
individually, Paretoanalysisitwas consideredreducingtherework of piston in an assembly line.

Volume 2, Issue 10, October 2014

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 2, Issue 10, October 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

Table.2: Monthly rework of Piston process sections

Fig 2: Pareto Analysis Graph

From
the
above
graph
the
outer
diameter
problemis31.64%individually,Paretoanalysisitwas
consideredreducingtherework of outer diameter of the piston in an assembly line.

6. SELECTION OF FACTORS AND THEIR LEVELS

The identified process parameters affecting the grinding process and their levels are shown in table 3.
Table 3: Factors and their Levels

7. SELECTION OF ORTHOGONAL ARRAY

Orthogonal Array gives more reliable estimates of the factor with less number of experiments when compared with
traditional methods, such as one factor at a time. In this project, four parameters at three levels each have been
selected(34). Hence L9 Orthogonal Array is selected, which is the smallest possible orthogonal array (suggested by
Taguchi), which meets the requirements of this project.

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 2, Issue 10, October 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

8. CONDUCTING THE EXPERIMENTS

The experiments were conducted on grinding machine using EN8 work piece as dictated by L9 Orthogonal Array.
Table 4 displays the experimental layout plan of L9 Orthogonal Array and recorded responses.
Table 4: Expt. Layout with their Responses

9. MATRIX EXPERIMENT DETAILS

The Signal to noise ratio was computed for each of the trials using the quality characteristic condition nominal-the-best
type.
9.1. Analysis of Mean (ANOM)
ANOM is the process of estimating the factor effects based on S/N ratio. This process is mainly used for determining
the optimal levels.
Table 5: Results of ANOM

Figure3: Plots of factor effects

Volume 2, Issue 10, October 2014

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 2, Issue 10, October 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

From the fig.3 it is observed that factors A3, B2, C1& D1 are having the highest S/N ratio. Hence these are the optimal
levels.
9.2 Analysis of Variance (ANOVA)
The relative magnitude of the factor effects can be determined using analysis of variance.
Table 6: ANOVA Table for S/N Ratio

After pooling the factors B and D the mean scale of error which is also known as the variance of error. i.e. (e2) =
12.5325 (dB) 2.
9.3 Confirmation Experiments
After conducting the experiments at optimal level combination A3, B2, C1& D1 the responses are given in table
Table 7: Conducted Confirmation experiment

Table-8 Confirmatory Test Result

9.4 Resultsdrawn from Confirmation Experiments

The predicted error i.e. difference between an observed value and the predicted value is within the two standard
deviation limits. Hence, the above model is adequate.
Here the prediction error is less than two standard deviation confidence levels, which indicate that the additive
model of is adequate.

10. CONCLUSIONS
The following conclusions were drawn from current investigations
Rework in assembly line is reduced from optimal level settings of process parameters.
All factors considered contribute to the performance characteristics.
By reducing depth of cut rework can be reduced in an assembly line.

Volume 2, Issue 10, October 2014

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 2, Issue 10, October 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

By increasing the cutting speed rework can be reduced.

The concept of ANOVA and S/N ratio is used to determine the effect and influence of process parameters namely
cutting speed, feed rate, depth of cut and material hardness is studied on output responses, and found that the
developed model is significant.

REFERENCES
[1] M.Janardhan and Dr.A.Gopala Krishna, Determination and Optimization of Cylindrical Grinding Process
parameters using Taguchi method and Regression analysis, International Journal of Engineering Science and
Technology (IJEST) Vol. 3 No. 7 July 2011.
[2] M.A. Kamely, S.M. Kamil, and C.W. Chong Mathematical Modeling of Surface Roughness in Surface Grinding
Operation, international journal of engineering &natural sciences 5:3 2011(146-149).
[3] Phadke.M.S. Quality Engineering Using Robust Design, Prentice Hall, International, New Jersey, 1989.
[4] Ross.P.J. Taguchi Techniques for Quality Engineering, McGraw Hill Inc., U.S.A, 1998
[5] Jae-SeobKwak, Application of Taguchi and
[6] response surface methodologies for geometric error in surfacegrinding process, International Journal of Machine
Tools & Manufacture 45 (2005) 32733.
[7] Mustafa Kemal Klekc,Analysis of process parameters for a surface Grinding process based on the Taguchi
method, Materials and technology 47(2013) 1,105-109.
[8] Bagchi, T. P., Taguchi Methods Explained Practical Steps to Robust Design, Prentice Hall of India, New
Delhi,1993.
[9] Gaitonde, V. N., et al., Optimization of product mix in a Dry Cement Manufacturing Plant, proceedings of the
National conference on advance trends in mechanical engineering research and development, J.N.T.U. collage of
engineering, Anantapur, 2002, 641-643.
[10] KirankumarRamakantraoJagtap,Optimization of Cylindrical Grinding process parameters for AISI 1040 steel
using Taguchi Method,IJMETVolume 3, Issue 1, January- April (2012), pp. 226-234.

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