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 an Introduction to the problem Roundness of circular hole to be Nominal, EW% to be

minimized and MRR to be maximized

Team members

Duration start date 27-Sep-06

Date today 21-Mar-19

Last Modified on 2-Mar-2007

password info for P. R. Apte: L9**** ==> L9 :- upto 4 control factors with 3 levels each
mbai-400 076, India
ac.in/~apte

M process
YOU MAY OVER-WRITE ON
THE 'orange' TEXT

IN ALL THE SHEETS

ole to be Nominal, EW% to be
be maximized
 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) the NoIsE factors. Effect of these will be captured
each experiment (Hard/Soft + High/Low temperatu

STEP 3: Identify Quality Characteristics and Objective Function The objective of the Taguchi experimentation is to
(1) keep roundness of holes at Nominal value
(2) increase MRR and (3) reduce the Electrode W

STEP 4: Identify Control Factors and their Levels Control Factors are (1) Pulse-On Time, (2) Gap Cu
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

umbai-400 076, India
.ac.in/~apte

TODAY
21-Mar-19

rocess optimization

he material and Bath temperature are considered to be

Effect of these will be captured by using 4 samples for
(Hard/Soft + High/Low temperatures)

he Taguchi experimentation is to
ss of holes at Nominal value
and (3) reduce the Electrode Wear %

re (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.

Roundness of hole YES

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

9 5

You may overtype

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

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

"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
empty

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

Control Factors Assigned to columns

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

1 P1 G1 B1 empty
2 P1 G2 B2 empty
3 P1 G3 B3 empty

4 P2 G1 B2 empty
5 P2 G2 B3 empty
6 P2 G3 B1 empty

7 P3 G1 B3 empty
8 P3 G2 B1 empty

9 P3 G3 B2 empty

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
F16

1 2 3 4 5 6 7 8 9

U1 U1 U1 U2 U2 U2 U3 U3 U3
V1 V2 V3 V1 V2 V3 V1 V2 V3

meas meas meas meas meas meas meas meas meas

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

8.90E+00 8.91E+00 8.92E+00 8.93E+00 8.94E+00 8.95E+00 8.96E+00 8.97E+00 8.98E+00

8.80E+00 8.82E+00 8.84E+00 8.86E+00 8.88E+00 8.90E+00 8.92E+00 8.94E+00 8.96E+00

8.90E+00 8.93E+00 8.96E+00 8.99E+00 9.02E+00 9.05E+00 9.08E+00 9.11E+00 9.14E+00

8.70E+00 8.71E+00 8.72E+00 8.73E+00 8.74E+00 8.75E+00 8.76E+00 8.77E+00 8.78E+00

8.60E+00 8.62E+00 8.64E+00 8.66E+00 8.68E+00 8.70E+00 8.72E+00 8.74E+00 8.76E+00

8.70E+00 8.74E+00 8.78E+00 8.82E+00 8.86E+00 8.90E+00 8.94E+00 8.98E+00 9.02E+00

8.50E+00 8.51E+00 8.52E+00 8.53E+00 8.54E+00 8.55E+00 8.56E+00 8.57E+00 8.58E+00

8.50E+00 8.55E+00 8.60E+00 8.65E+00 8.70E+00 8.75E+00 8.80E+00 8.85E+00 8.90E+00

8.50E+00 8.55E+00 8.60E+00 8.65E+00 8.70E+00 8.75E+00 8.80E+00 8.85E+00 8.90E+00

DATA COPIED FROM THE DATA-INPUT 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"

TA-INPUT 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 9
expt.

1 8.90E+00 8.91E+00 8.92E+00 8.93E+00 8.94E+00 8.95E+00 8.96E+00 8.97E+00 8.98E+00

2 8.80E+00 8.82E+00 8.84E+00 8.86E+00 8.88E+00 8.90E+00 8.92E+00 8.94E+00 8.96E+00

3 8.90E+00 8.93E+00 8.96E+00 8.99E+00 9.02E+00 9.05E+00 9.08E+00 9.11E+00 9.14E+00

4 8.70E+00 8.71E+00 8.72E+00 8.73E+00 8.74E+00 8.75E+00 8.76E+00 8.77E+00 8.78E+00

5 8.60E+00 8.62E+00 8.64E+00 8.66E+00 8.68E+00 8.70E+00 8.72E+00 8.74E+00 8.76E+00

6 8.70E+00 8.74E+00 8.78E+00 8.82E+00 8.86E+00 8.90E+00 8.94E+00 8.98E+00 9.02E+00

7 8.50E+00 8.51E+00 8.52E+00 8.53E+00 8.54E+00 8.55E+00 8.56E+00 8.57E+00 8.58E+00

8 8.50E+00 8.55E+00 8.60E+00 8.65E+00 8.70E+00 8.75E+00 8.80E+00 8.85E+00 8.90E+00

9 8.50E+00 8.55E+00 8.60E+00 8.65E+00 8.70E+00 8.75E+00 8.80E+00 8.85E+00 8.90E+00

Feed the data in these You can have upto 16

rows and columns measurements per expt

meas.
2 NF with
2-levels each = 4
3 NF with
How to use NoIsE Factors for 2-levels each = 4
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= 6
2-4 NF with
3-levels each = 9
 10 11 12 13 14 15 16

8.99E+00 9.00E+00 9.01E+00

8.98E+00 9.00E+00 9.02E+00

9.17E+00 9.20E+00 9.23E+00

8.79E+00 8.80E+00 8.81E+00

8.78E+00 8.80E+00 8.82E+00

9.06E+00 9.10E+00 9.14E+00

8.59E+00 8.60E+00 8.61E+00

8.95E+00 9.00E+00 9.05E+00

8.95E+00 9.00E+00 9.05E+00

Blanks will not affect the results

of mean, Variance and SN Ratio

factorial
L4 Orthogonal
Array
 factorial

L9 Orthogonal
Array
 Repetitions or
Expt. No. Measurements for each 1 2 3 4 5 6 7 8 9
expt.

1 8.90E+00 8.91E+00 8.92E+00 8.93E+00 8.94E+00 8.95E+00 8.96E+00 8.97E+00 8.98E+00

2 8.80E+00 8.82E+00 8.84E+00 8.86E+00 8.88E+00 8.90E+00 8.92E+00 8.94E+00 8.96E+00
3 8.90E+00 8.93E+00 8.96E+00 8.99E+00 9.02E+00 9.05E+00 9.08E+00 9.11E+00 9.14E+00
4 8.70E+00 8.71E+00 8.72E+00 8.73E+00 8.74E+00 8.75E+00 8.76E+00 8.77E+00 8.78E+00
5 8.60E+00 8.62E+00 8.64E+00 8.66E+00 8.68E+00 8.70E+00 8.72E+00 8.74E+00 8.76E+00
6 8.70E+00 8.74E+00 8.78E+00 8.82E+00 8.86E+00 8.90E+00 8.94E+00 8.98E+00 9.02E+00
7 8.50E+00 8.51E+00 8.52E+00 8.53E+00 8.54E+00 8.55E+00 8.56E+00 8.57E+00 8.58E+00
8 8.50E+00 8.55E+00 8.60E+00 8.65E+00 8.70E+00 8.75E+00 8.80E+00 8.85E+00 8.90E+00
9 8.50E+00 8.55E+00 8.60E+00 8.65E+00 8.70E+00 8.75E+00 8.80E+00 8.85E+00 8.90E+00

The data has been brought You can have upto 16

from previous sheet and measurements per
this sheet is protected expt
 SN Ratio
SN Ratio
10 11 12 13 14 15 16 Mean Variance (Mean)
(Nominal-the-
Best)

8.94E+00 7.50E-04 1.90E+01 5.03E+01

8.88E+00 3.00E-03 1.90E+01 4.42E+01
9.02E+00 6.75E-03 1.91E+01 4.08E+01
8.74E+00 7.50E-04 1.88E+01 5.01E+01
8.68E+00 3.00E-03 1.88E+01 4.40E+01
8.86E+00 1.20E-02 1.89E+01 3.82E+01
8.54E+00 7.50E-04 1.86E+01 4.99E+01
8.70E+00 1.88E-02 1.88E+01 3.61E+01
8.70E+00 1.88E-02 1.88E+01 3.61E+01

Blanks will not affect the

results of mean, Variance S/N Ratios for
and SN Ratio Nominal-the-best and Mean
 Main Effects
Column #1 Column #2
Expt. No. SN Ratio (Nominal-the-Best) Pulse-On Time Gap Current
OV Mean P1 P2 P3 G1
1 50.28 50.28 50.28
2 44.20 44.20
3 40.81 40.81
4 50.08 50.08 50.08
5 44.00 44.00
6 38.16 38.16
7 49.88 49.88 49.88
8 36.06 36.06
9 36.06 36.06

Sum 135.3 132.2 122.0 150.2

Factor-
43.28 45.09 44.08 40.67 50.08
Effects

OV-Mean 43.28 43.28

43.28 ### 43.28 ### 43.28 43.28 43.28 ### 43.28
Sum of Sq
due to
mean 16858

GrandTotal
Sum of 17135
Squares
Total SSQ 277
ects
Column #2 Column #3 Column #4
Gap Current Bi-Pulse Current empty
G2 G3 B1 B2 B3 empty empty empty Ov-Mean
50.28 50.28
44.20 44.20 44.20
40.81 40.81 40.81
50.08 50.08
44.00 44.00 44.00
38.16 38.16 38.16
49.88 49.88
36.06 36.06 36.06
36.06 36.06 36.06

124.3 115.0 124.5 130.3 134.7 130.3 132.2 127.0

41.42 38.34 41.50 43.45 44.90 43.45 44.08 42.32

43.28 43.28 43.28

43.28 43.28 ###### 43.28 43.28 43.28 ### 43.28 43.28 43.28 ###
 Main Effects
Column #1 Column #2
Expt. No. SN Ratio (Mean) Pulse-On Time Gap Current
OV-Mean P1 P2 P3 G1
1 19.03 19.03 19.03
2 18.97 18.97
3 19.10 19.10
4 18.83 18.83 18.83
5 18.77 18.77
6 18.95 18.95
7 18.63 18.63 18.63
8 18.79 18.79
9 18.79 18.79

Sum 57.1 56.5 56.2 56.5

Factor-
18.87 19.03 18.85 18.74 18.83
Effects

OV-Mean 18.87 18.87

18.87 ### 18.87 ### 18.87 18.87 18.87 ### 18.87
Sum of Sq
due to
mean 3206

GrandTotal
Sum of 3206
Squares
Total SSQ 0
ects
Column #2 Column #3 Column #4
Gap Current Bi-Pulse Current empty
G2 G3 B1 B2 B3 empty empty empty Ov-Mean
19.03 19.03
18.97 18.97 18.97
19.10 19.10 19.10
18.83 18.83
18.77 18.77 18.77
18.95 18.95 18.95
18.63 18.63
18.79 18.79 18.79
18.79 18.79 18.79

56.5 56.8 56.8 56.6 56.5 56.6 56.5 56.7

18.84 18.95 18.92 18.86 18.83 18.86 18.85 18.91

18.87 18.87 18.87

18.87 18.87 ###### 18.87 18.87 18.87 ### 18.87 18.87 18.87 ###
 YOU CAN MODIFY THE CHART -
PARTICULARLY THE Y-AXIS

Main Factor Effects Quality char

S-N Ratio Nominal-the-best Main Effects - Ov Mean
S-N Ratio for mean mean

60.00 19.10

50.00 19.00
S-N Ratio (Nominal-the-best) in dB

40.00 18.90

S-N Ratio (Mean) in dB

30.00 18.80

20.00 18.70

10.00 18.60

0.00 18.50
OV Mean

P1
P2
P3

G1
G2
G3

B1
B2
B3

Ov-Mean
empty
empty
empty
Control Factors and Their Levels
Quality char Name
Effects - Ov Mean
n

19.10

19.00

18.90
S-N Ratio (Mean) in dB

18.80

18.70

18.60

18.50
Ov-Mean

vels
 Main Factor Effects
S-N Ratio Nominal-the-best Main Effects - Ov Mean
S-N Ratio for mean mean
60.00 19.10

50.00
S-N Ratio (Nominal-the-best) in dB

19.00

40.00 18.90

S-N Ratio (Mean) in dB

30.00 18.80

20.00 18.70

10.00 18.60

0.00 empty 18.50

G2
G3

empty
empty
OV Mean

P1
P2
P3

G1

Ov-Mean
B1
B2
B3

Control Factors and Their Levels

ects
Ov Mean

9.10

9.00

8.90
S-N Ratio (Mean) in dB

8.80

8.70

8.60

8.50
 LEVELS
CONTROL FACTORS \ LEVELS 1 2 3 Degrees Sum of Mean
of Squares Square
Freedo
m

Pulse-On Time 45.09 44.08 40.67 2 32 16

Gap Current 50.08 41.42 38.34 2 222 111

Bi-Pulse Current 41.50 43.45 44.90 2 17 9

empty 43.45 44.08 42.32 0 0 0

Ov-Mean 43.28 43.28 43.28

Total sum of Squares due to Factor Effects 272
Total sum of Squares = grand Total - 9*mean sq 277

Error Variance (unpooled) 2 5

Error Variance (unpooled) per degree of freedom 2.39
(Error Variance pooled)) 2 5

Error Variance per degree of freedom 2.39

Error Bar for each CF level = 2*SQRT(error var. per DF / repetition of each level) = 1.78

Prediction error variance (for 5 to 6 repititions) = sum of sq for error / neff = 3.13

95% confidence interval for pred. err = +-2*sqrt(pred err) = 3.54

OV-MEAN 43.28 43.28 43.28 43.28

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

12 7 no no 7 +- 1.78 dB

80 47 no no 47 +- 1.78 dB

6 4 no no 4 +- 1.78 dB

- 0 yes yes - +- 1.78 dB

no. of unpooled CFs = 3

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

(nrepeat for each level) = 1.11

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

expts = 5 therefore neff = 0.76
prediction error = error variance per degree of
ffreedom/neff 3.12792673
 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 P1

Column 2 Gap Current G1 G2 G3 1 G1

Column 3 Bi-Pulse Current B1 B2 B3 1 B1

Column 4 empty empty empty empty - -

50.1
53.65 46.57

See the 'RESULTS' here 2.08E-03 to 4.69E-03

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

P1 12 1.81 SIGNIFICANT 7

G1 80 6.80 D O M I N A N T 47

B3 6 -1.78 SIGNIFICANT 4

- - 0.00 neutral/negligible- -

Ov-Mean 43.28

S/N Ratio 50.11

"+-" error in dB 3.54

'Roundness of
hole' as fraction
std_dev/Mean
3.12E-03

Range
Center Value