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

P.R. Parate; R.B. Yarasu

doi:10.15282/jmes.4.2013.12.0045

Authors

P.R. Parate Government College of Engineering, Amravati, India
R.B. Yarasu Government College of Engineering, Amravati, India

DOI:

https://doi.org/10.15282/jmes.4.2013.12.0045

Keywords:

Lapping; cast iron; MRR; Taguchi; ANOVA.

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.

References

Belavendram, N. 2010. Application of genetic algorithms for robust parameter optimization. International Journal of Automotive and Mechanical Engineering, 2: 211-220.

Chunhui, C., Korach, C.S., & Kao, I. 2011. Experimental study and modeling of lapping using abrasive grits with mixed sizes. Journal of Manufacturing Science and Engineering, 133(3): 1-8.

Evans C.J., Paul, E., Dornfeld, D., Lucca, D.A., Byrne, G., Tricard, M., & Klocke F. 2003 Material removal mechanism in lapping and polyshing. CIRP Annals- Manufacturing Technology, 52(2): 611-633.

Kang, J., & Hadfield, M. 2001 Parameter optimization by Taguchi Methods for finishing advanced ceramic balls using a novel eccentric lapping machine. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 215(1):69-78.

Kang, J., & Hadfield, M. 2005. The effects of lapping load in finishing advanced ceramic balls on a novel eccentric lapping machine. Journal of Engineering Manufacture, Vol. 219(7): 505-513.

Khan, M.A.R., Rahman, M.M., Kadirgama, K., Maleque, M.A., & Ishak, M. 2011. Prediction of surface roughness of Ti-6Al-4V in electrical discharge machining: a regression model. Journal of Mechanical Engineering and Sciences, 1: 16-24.

Najiha, M.S., Rahman, M.M., Yusoff, A.R., & Kadirgama, K. 2012. Investigation of flow behavior in minimum quantity lubrication nozzle for end milling processes. International Journal of Automotive and Mechanical Engineering, 6: 766-774.

Taguchi, G.H. 1987. Taguchi methods orthogonal arrays and linear graphs, tools for quality engineering. Dearborn, MI: American Supplier Institute, pp. 35-38.

Yusoff, A.R. 2011. Literature review of optimization technique for chatter suppression in machining. Journal of Mechanical Engineering and Sciences, 1: 47-61.