Application of Taguchi and ANOVA in Optimization of Process Parameters of Lapping Operation for Cast Iron

Abstract

Lapping appears like a miraculous process, because it can produce surfaces that are perfectly flat, perfectly round, perfectly smooth, perfectly sharp, or perfectly accurate. Under the correct circumstances, it can impart or improve precise geometry (flatness, roundness, etc.), improve surface finish, improve surface quality, achieve high dimensional accuracy (length, diameter, etc.), improve angular accuracy (worm gears, couplings, etc.), improve fit, and above all, sharpen the tools. This paper presents research on calculating the material removal rate for a machining component by the lapping process. The cast iron sample with an outer diameter of 50 mm and an inner diameter of 45 mm was tested on a single plate tabletop lapping machine. Experiments based on design of experiments were conducted by varying lapping load, lapping time, paste concentration, lapping fluid, and by using different types of abrasives. The Taguchi statistical method has been used in this work. Optimum machining parameters for material removal rate are estimated and verified with experimental results and are found to be in good agreement. The confirmation test exhibits high material removal rate by using Al2O3 abrasive particles together with oil as a carrier fluid under the impression of high load. Further material removal rate increases with an increase in lapping load and time.