Quality improvement using Taguchi method in shot blasting process

H. Jamaluddin; J.A. Ghani; B. Md Deros; M.N. Ab Rahman; R. Ramli

doi:10.15282/jmes.10.2.2016.22.0206

Authors

H. Jamaluddin Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia.
J.A. Ghani Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia.
B. Md Deros Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia.
M.N. Ab Rahman Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia.
R. Ramli Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia.

DOI:

https://doi.org/10.15282/jmes.10.2.2016.22.0206

Keywords:

Quality improvement; Taguchi method; blasting process; capability index; tolerance setting

Abstract

This paper presents the reliability of the Taguchi Method for improving the product and process quality in the industrial environment. The purpose is to signify the applicability of the Taguchi method in process optimization. The application of the Taguchi design of experiment (DOE) is widely reported and published but the success of the Taguchi method as a prominent tool in solving the industrial problem is not disclosed. In this study, the shot blasting process was chosen with two control factors of blasting speed and turntable speed; both factors were set at three levels. The rotor blasting speed and turntable speed were set between 2500-2900 rpm and 35-45 rpm respectively. From the result obtained, it was found that the surface roughness capability index improved from Cpk -0.14 to 1.06, i.e. an improvement in the S/N ratio of 113% (from 12.78 dB to 27.21 dB). The main factor that significantly affected the surface roughness variation was rotor blasting speed which contributed 56.9% of the total effects. The optimum setting was by setting the rotor blasting speed at 2900 RPM and the turntable speed at 39 RPM. The estimated tolerance setting was found to be 1% and 2% for the rotor blasting speed and turntable speed respectively. The optimum setting resulted in the improvement of the surface roughness, i.e. the quality of the part. Taguchi method is an effective way to determine optimum performance through the analysis of optimum combination parameter setting.

References

Antony J, Bardhan Anand R, Kumar M, Tiwari M. Multiple response optimization using Taguchi methodology and neuro-fuzzy based model. Journal of Manufacturing Technology Management. 2006;17:908-25.

Nalbant M, Gökkaya H, Sur G. Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning. Materials & Design. 2007;28:1379-85.

Jamil M, Ng E. Statistical modeling of electrode based thermal therapy with Taguchi based multiple regression. International Journal of Thermal Sciences. 2013;71:283-91.

Badkar DS, Pandey KS, Buvanashekaran G. Parameter optimization of laser transformation hardening by using Taguchi method and utility concept. The International Journal of Advanced Manufacturing Technology. 2011;52:1067-77.

Xu W, Ogrodnik PJ, Goodwin MJ, Bancroft GA. The Stability Analysis of Hydrodynamic Journal Bearings Allowing for Manufacturing Tolerances. Part I: Effect Analysis of Manufacturing Tolerances by Taguchi Method. 2009 International Conference on Measuring Technology and Mechatronics Automation: IEEE; 2009. p. 164-7.

Zhang F, Wang Z, Yang M. Assessing the applicability of the Taguchi design method to an interrill erosion study. Journal of Hydrology. 2015;521:65-73.

Ghani JA, Choudhury I, Hassan H. Application of Taguchi method in the optimization of end milling parameters. Journal of Materials Processing Technology. 2004;145:84-92.

Tasirin SM, Kamarudin SK, Ghani JA, Lee K. Optimization of drying parameters of bird’s eye chilli in a fluidized bed dryer. Journal of food engineering. 2007;80:695-700.

Jaharah A, Che Hassan C, Ghazali MJ, Sulong AB, Omar MZ, Nuawi MZ, et al. Performance of uncoated carbide cutting tool when machining cast iron in dry cutting condition. International Journal of Modern Physics B. 2009;23:1796-802.

Ibrahim G, Haron CHC, Ghani JA, Arshad H. Taguchi optimization method for surface roughness and material removal rate in turning of Ti-6Al-4V ELI. International Review of Mechanical Engineering. 2010;4:216-21.

Chen G-L, Chen G-B, Li Y-H, Wu W-T. A study of thermal pyrolysis for castor meal using the Taguchi method. Energy. 2014;71:62-70.

Roy RK. A Primer on the Taguchi Method. 1st ed. New York. Van Nosrrand Reinhold: Society of Manufacturing Engineers; 1990.

El-Haik KY-B, Yang K. Design for Six Sigma, A Roadmap for Product Development. RR Donnelly, SAD, str. 2003;21.

Su C-T, Lin C-M, Hsu C-C. Optimization of the optical whiteness ratio for flexible display by using Taguchi's dynamic approach. IEEE Transactions on Semiconductor Manufacturing. 2012;25:2-15.

Antony J, Somasundarum V, Fergusson C, Blecharz P. Applications of Taguchi approach to statistical design of experiments in Czech Republican industries. Quality improvement using Taguchi method in shot blasting process, International Journal of Productivity and Performance Management. 2004;53:447-57.

Phadke MS. Quality engineering using robust design: Prentice Hall PTR; 1995.

Dowey S, Matthews A. Taguchi and TQM: Quality issues for surface engineered applications. Surface and Coatings Technology. 1998;110:86-93.

Kalpakjian S, Schmid SR, Sekar KV. Manufacturing engineering and technology. 5 ed: Prentice Hall; 2006.

Arifvianto B, Suyitno K, Mahardika M. Influence of grit blasting treatment using steel slag balls on the subsurface microhardness, surface characteristics and chemical composition of medical grade 316L stainless steel. Surface and Coatings Technology. 2012;210:176-82.

Park S. Robust design and analysis for quality engineering: Boom Koninklijke Uitgevers; 1996.

Chen D-C, Chen C-F. Use of Taguchi method to develop a robust design for the shape rolling of porous sectioned sheet. Journal of Materials Processing Technology. 2006;177:104-8.

Ghazali FA, Manurung YH, Mohamed MA, Alias SK, Abdullah S. Effect of process parameters on the mechanical properties and failure behavior of spot welded low carbon steel. Journal of Mechanical Engineering and Sciences. 2015;8:1489-97.

Pedrotty F. Metal cleaning and finishing by the airless abrasive blasting process. Production Engineers Journal, Institution of. 1957;36:128-35.

Naidu NR, Raman SGS. Effect of shot blasting on plain fatigue and fretting fatigue behaviour of Al–Mg–Si alloy AA6061. International Journal of Fatigue. 2005;27:323-31.

Radhakumari M, Ball A, Bhargava SK, Satyavathi B. Optimization of glucose formation in karanja biomass hydrolysis using Taguchi robust method. Bioresource Ttechnology. 2014;166:534-40.

Kolli M, Kumar A. Effect of dielectric fluid with surfactant and graphite powder on Electrical discharge machining of titanium alloy using Taguchi method. Engineering Science and Technology, an International Journal. 2015;18:524-35.

Verma V, Murugesan K. Optimization of solar assisted ground source heat pump system for space heating application by Taguchi method and utility concept. Energy and Buildings. 2014;82:296-309.

Elangovan S, Prakasan K, Jaiganesh V. Optimization of ultrasonic welding parameters for copper to copper joints using design of experiments. The International Journal of Advanced Manufacturing Technology. 2010;51:163-71.

Apte P. A 3-Day Course on Taguchi Method for Process and Product Optimization. IEEE-EDS Malaysia Chapter, Puri Pujangga, UKM, Bangi, Malaysia. 2010:6-8.

Ishak M, Shah L, Aisha I, Hafizi W, Islam M. Study of resistance spot welding between aisi 301 stainless steel and AISI 1020 carbon steel dissimilar alloys. Journal of Mechanical Engineering and Sciences. 2014;6:793-806.

Maghsoodloo S, Ozdemir G, Jordan V, Huang C-H. Strengths and limitations of Taguchi's contributions to quality, manufacturing, and process engineering. Journal of Manufacturing systems. 2004;23:73-126.

Stamatis DH. Six Sigma and Beyond: Design of Experiments: CRC Press; 2002.

Anderson MJ, Whitcomb PJ. DOE simplified: practical tools for effective experimentation. 2nd ed: CRC Press; 2007.

Zhang JZ, Chen JC, Kirby ED. Surface roughness optimization in an end-milling operation using the Taguchi design method. Journal of Materials Processing Technology. 2007;184:233-9.

Parate P, Yarasu R. Application of Taguchi and ANOVA in optimization of process parameters of lapping operation for cast iron. Journal of Mechanical Engineering and Sciences. 2013;4:479-87.

Prakash NA, Gnanamoorthy R, Kamaraj M. Friction and wear behavior of surface nanocrystallized aluminium alloy under dry sliding condition. Materials Science and Engineering: B. 2010;168:176-81.

Chang Y. Interval estimation of capability index Cpmk for manufacturing processes with asymmetric tolerances. Computers & Industrial Engineering. 2009;56:312-22.

Walpole RE, Myers RH, Myers SL, Ye K. Probability and statistics for engineers and scientists: Macmillan New York; 2007.