Process Parametric Optimization of Impact Test Using Taguchi and ANOVA Approach

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 4, Issue 1, January 2016
Process parametric optimization of Impact test

using Taguchi and ANOVA approach
Veerabhadrappa Algura, Dr. V.R. Kabadib, Dr. Ganechari S Mc, A M Shiva Prakash Swamyd, B
Naveen Kumare
a
Department of Industrial and Production Engineering, Rao Bahadur Y Mahabaleshwarappa Engineering College, Bellary,
Karnataka, India,
b
Department of Mechanical Engineering, Nitte Meenakshi Institute of Technology, Yelahanka, Bengaluru,

c
Thakur Polytechnic, Kandivali, Mumbai, Maharashtra State, India,
Department of Mechanical Engineering, Rao Bahadur Y Mahabaleshwarappa Engineering College, Bellary, India.
M.Tech (Production Management), Department of Mechanical Engineering, Rao Bahadur Y Mahabaleshwarappa

Engineering College, Ballari, Karnataka, India
ABSTRACT
Impact testing methodology is finding the applications for determining the impact strength of the different materials. The
process implies hammering effect on the work material that determines how much mechanical energy required for failure of
any material. The aim of this research work is focused on the optimization of process parameters in order to maximize the
impact toughness using taguchi technique. The research work investigates the effect of process parameters on impact values.
An L9 orthogonal array was chosen for the design of experiment. The optimum process parameters were determined by using
signal-to-noise ratio. The levels of importance of process parameters on impact testing were obtained using analysis of
variance. The variation of impact properties with process parameters were mathematically modelled using the regression
analysis. The results obtained using design of experiments were validated analytically and graphically shows that work material
affected the impact toughness most significantly factor of Izod impact value. The material and height of the hammer are the
most significant factor of Charpy impact value.
Keywords: Charpy test, Izod test, Regression Analysis, Taguchi Method, Zinc - Aluminium alloy
1. INTRODUCTION
Zinc based cast alloys, commonly referred to as ZA alloys, has been developed during 1960 and is now increasing in
commercial usage. These alloys exhibit mechanical properties equal to or exceeding those of Conventional zinc die
casting alloys and those of cast iron, aluminium and copper alloys. Zinc-aluminium cast alloys have been designated as
ZA-8, ZA-12, and ZA-27[1-8]. Adding aluminium improves the fluidity and castability of the zinc based (ZA) alloys.
An important aspect that makes these alloys attractive is the low energy requirement to achieve casting, due to their low
melting point as compared with aluminum, brass and iron alloys. The main advantages of this alloy are low cost, high
resistance to wear, feature clean, low temperature, supreme castability, high as- cast strength and hardness, Corrosion
resistance as compared to standard bronze. Recent investigations have been focused on the Characterization of the ZA
alloys and modified versions such as corrosion, wear and other mechanical properties [9-18].
Shuqing Yan et.al (2010) studied the influence of different Al contents on the Mechanical characterization, the results
reveals that 27%Al content shows the higher ultimate strength and elongation. Nirmala et.al(2014) studied the
microstructure features of ZA27 alloy by varying nickel from 1 to 3wt%, addition of nickel resulted in the formation of
intermetallic compounds . Yuanyun Li et.al (1995) studied the mechanical and tribological properties by adding the
rare earth as a modifying elements to the zinc based alloy, ZMJ proven has an excellent engineering Material by
comparing its mechanical and wear properties with those of ZA alloys. Aleksandar Vencl et.al (2014) studied the
influence of silicone and strontium alloys on ZA-27 alloy and to examine the tribological properties.
However there is not much information available on effect of varying the process parameters of impacting testing
machine. The present study aims at studying the influence of process parameters on impact testing machine of zinc
aluminium alloy using taguchi method. Further analysis of variance is carried out to identify the most significant
process parameters.
2. IMPACT EXPERIMENT
Toughness is a measure of the amount of energy a material can absorb before fracturing. It becomes of engineering
importance when the ability of a material to withstand an impact load without fracturing is considered. Impact test
conditions were chosen to represent those most severe relative to the potential for fracture
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Two standardized tests, the Charpy and Izod, are commonly used to measure Impact Energy (sometimes referred to as
Notch Toughness). The Charpy V-notch (CVN) technique is most commonly used in the United States. For both
Charpy and Izod, a V-notch is machined into a bar specimen with a square cross section. A standard V-notch test
apparatus is schematically illustrated in Figure 1. The load is applied as an impact blow from a weighted pendulum
hammer that is released from a cocked position at a fixed height "h". The specimen is positioned at the base as shown.
Upon release, a knife edge mounted on the pendulum strikes and fractures the specimen at the notch, which acts as a
point of stress concentration for the high velocity impact blow. The pendulum continues its swing, rising to a maximum
height "h", which is lower than "h". Based on the difference between h and h, the energy absorption of the specimen
is computed.
Fig1: Schematic representation of Impact testing machine

3. EXPERIMENTAL DETAILS
Materials: The Material preparation of zinc-aluminium alloys with varying concentrations of Al (8, 12 & 27 wt %)
were prepared in a crucible furnace. After the alloys were melted completely, the melts were fully stirred and
immediately poured into steel mould. The processing temperatures of the melts were controlled below 7000C to avoid
loss of Zn. Raw materials were melted in a graphite crucible. After degassing the molten metal was poured into a
mould, which has pre heated an approximately up to 1500C in open air.
Table1: Chemical composition of experimental alloys (in mass percent, by wt. chemical analysis)
Al
Cu
Mg
Zn
ZA-8
8%
1.3%
0.03%
Balance
ZA-12
12%
1.22%
0.03%
Balance
ZA-27
27%
2.5%
0.03%
Balance
3.1 Sample preparation

The rod shaped alloys are converted to specified samples as per required dimensions according to ASTM E 23 by
undergoing it through machining process of lathe and finishing them in end. The exact dimensions and configuration
of samples are mentioned below for Impact testing.
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V- Notched Izod type specimen

ISSN 2321-6441
V-notched Charpy type specimen
Fig.2: Samples for Impact strength test
4. METHODOLOGY
4.1Design of experiments
The design of experiments is the most power full tool for analyzing the influence of control factors on performance
output. Taguchi method systematically reveals the complex cause and effect relationship between design parameter and
performance. The three process parameters (work material, weight of hammer and height of hammer) and impact
energy absorbed (Impact value) was studied using L9 orthogonal array using MINITAB 16 software. In proposed work
ZA-8, ZA12 and ZA-27 alloys were selected for specimen. The various input parameters were taken under
experimental investigation and then model were prepared then again experimental work would be performed.
Therefore, 9 trials were conducted on both Izod and Charpy impact testing machine. The results obtained were
analyzed and model was produced using MINITAB 16. Taguchi method is used to find out the optimum condition of
significance of each factor.
In this study, higher is better is considered to maximize the impact strength of zinc aluminium alloys. For this case,
S/N ratio is calculated as a logarithmic transformation of loss of function as shown below:
S/N ratio =
----------- (1)
Where n is the number of observation and y is the observed data

In the experiment, there are three parameters at three levels. Values of variables at different level for Izod impact
testing as shown in the Table 2, and values of variables at different level for Charpy Impact Testing as shown in the
Table 3.
Table 2: Values of variables at different level for Izod Impact Testing
Table 3: Values of variables at different level for Charpy Impact Testing
The standard L9 orthogonal arrays is considered for the experiment to be carried out is shown in the table 4.
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Table 4: Standard L9 orthogonal array (Taguchi design)
Table 5: Results of Experimental run for Izod test
Table 6: Response Table for Signal to Noise Ratios
Table 7: Response Table for Means
Table 8: Results of Experimental run for Charpy test

Sl.No
Material
Weight
01
02
03
04
05
06
07
08
09
ZA-8
ZA-8
ZA-8
ZA-12
ZA-12
ZA-12
ZA-27
ZA-27
ZA-27
146.12
165.73
185.35
146.12
165.73
185.35
146.12
165.73
185.35
Height
(mm)
1562
1791
1994
1791
1994
1562
1994
1562
1791
Impact value of
Charpy test (J)
10
15
12
24
20
18
34
32
38
S/N
Ratio(db)
20.0000
23.5218
27.0437
27.6042
26.0206
25.1055
30.6296
30.1030
31.5957
Mean
10
15
20
24
20
18
34
32
38
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Table 9: Response Table for Signal to Noise Ratios

Level
1
2
3
Delta
Rank
A
21.70
26.24
30.78
9.07
1
B
26.08
26.55
26.09
0.47
3
C
25.07
27.57
26.08
2.50
2
Table 10: Response Table for Means

Level
1
2
3
Delta
Rank
A
12.33
20.67
34.67
22.33
1
B
22.67
22.33
22.67
0.33
3
C
20.00
25.67
22.00
5.67
2
5. RESULTS AND DISCUSSIONS

5.1 Signal-to-Noise ratio (S/N ratio)
In Taguchi method, the term signal represents the desirable value (mean) for the output characteristics and the term
noise represents the undesirable value for the output characteristics. It allows carrying out modeling and analysis of
the influence of process variables on the response variables. This optimization technique is carried out in a three stage
approach such as system design, parameter design and tolerance design. Based on taguchi method an orthogonal array
(OA) is considered to determine the optimal Impact test for both Izod and Charpy of Zinc Aluminium alloys. The
experiments were carried out to examine the influence of testing parameters on Impact test for both Izod and Charpy
test of zinc aluminium Alloy. The experiments were conducted according to L9 Orthogonal array as shown in Table 5
for Izod test and for Charpy test as shown in table 8. The first column is assigned by work material, second column is
assigned by Weight of hammer and the third column is assigned by Height of hammer. A total of 9 experiments were
conducted based on the run order generated by taguchi model. The response (S/N ratio) studied for the model is Impact
test for both Izod and Charpy test with the objective of Larger the better type of quality characteristics as shown in
the Table 6 and the mean is shown in the Table 7 for Izod impact test and Table 9 and Table 10for Charpy impact test.
The response was calculated for each level of process parameters. The process parameters, code and their levels are
shown in the Table 2 and 3 each process parameters having three levels. It suggests that from the Table 5 the optimum
conditions for Izod test are A3B2C3 and the Table 8 for Charpy test the optimum process parameters are A3B3C2. Fig 3
and Fig 4 shows the main effect plot for S/N ratios and main effect plot for mean for Izod impact test and . Fig 5 and
Fig 9 shows the main effect plot for S/N ratios and main effect plot for mean for Izod impact test.
M a in E f fe c ts P lo t f o r S N r a tio s
D a ta M e a n s
M a te ria l
36
W e ig h t
34
Mean of SN ratios
32
30
28
Z A -8
ZA 1 2
Z A -2 7
1 3 9 .7 5
1 5 9 .3 6
1 7 8 .9 8
H e ig h t
36
34
32
30
28
103 4
110 2
118 1
S ig n a l- to - n o is e : L a r g e r is b e tt e r
Fig. 3: Main Effects Plot for SN ratios (Izod test)
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Main Effects Plot for Means

Data Means
Material
60
W eight
50
Mean of Means
40
30
20
ZA -8
ZA 12
ZA -27
139.75
159.36
178.98
Height
60
50
40
30
20
1034
1102
1181
Fig. 4: Main Effects Plot for Means (Izod test)
Main Effects Plot for S N ratios

Data Means
Material
W eight
30
28
Mean of SN ratios
26
24
22
ZA -8
ZA -1 2
Height
ZA -2 7
1562
1791
1994
1 46 .1 2
1 6 5.7 3
1 8 5 .3 5
30
28
26
24
22
S ignal-to-noise: Larger is better
Fig. 5: Main Effects Plot for SN ratios (Charpy test)
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Main Effects Plot for Means

Data Means
Material
Weight
35
30
Mean of Means
25
20
15
ZA-8
ZA-12
Height
ZA-27
1562
1791
1994
146.12
165.73
185.35
35
30
25
20
15
Fig. 6: Main Effects Plot for Means (Charpy test)

5.2 ANOVA
The conducted experimental results were analyzed by using Analysis of Variance (ANOVA) which is used to examine
the influence of wear parameters like Normal pressure and Sliding speed. By using ANOVA, it can be decided which
independent factor dominates over the other and the percentage contribution of that particular independent variable.
This analysis was carried out for a level of 5% significance that is up to a confidence level of 95%. Sources with a Pvalue less than 0.05 were considered to have a statistically significant contribution to the performance measures.
Tables 11 and 12 show the results of ANOVA analysis for Izod and Charpy test of Zinc Aluminium alloy. Table shows
the Material (97.41%) has highest influence on Izod impact test followed by Height (2.17%) and Weight (0.21%).
Table shows the Material (93.86%) has highest influence on Charpy impact test followed by Height (6.09%) and
Weight (0.02%). By seeing the table the work material has considers to have a statistically significant contribution for
Izod and Charpy impact test.
Table 11: Analysis of Variance for Impact value of Izod test
Table 12: Analysis of Variance for Impact value of Charpy test

Source
DF
Seq SS
Adj SS
Adj MS
Work Material
Weight
Height
Error
Total
2
2
2
2
8
764.22
0.22
49.56
0.22
814.22
764.22
0.22
49.56
0.22
382.11
0.11
24.78
0.11
3439.00
1.00
223.00
0.000
0.500
0.004
% of
contribution
93.86
0.02
6.09
0.03
100.00
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ISSN 2321-6441
5.3 Regression Equation

A multiple linear regression model is used to develop using statistical software MINITAB 16. This model gives the
correlation between the effective factors (Work Material, Weight and Height) and the Impact test for Izod and Charpy
test (quality characteristic) to observed data.
For Izod Test

Material
ZA-8 Impact value of Izod test = 65.7105 - 0.0085034 Weight - 0.0383076 Height ----Eqn (2)
ZA12 Impact value of Izod test = 72.7105 - 0.0085034 Weight - 0.0383076 Height ----Eqn (3)
ZA-27 Impact value of Izod test = 101.711 - 0.0085034 Weight - 0.0383076 Height ----Eqn (4)
R-Sq = 99.79%
For Charpy Test
Material
ZA-8
Impact value of Charpy test = 3.31991 + 1.44395e-006 Weight + 0.00505696 Height
Eqn (5)
ZA-12
Eqn (6)
ZA-27
Eqn (7)
R-Sq = 99.97%
From Eq (4.1), Eq(4.2) and Eq(4.3) noticed that the negative value of coefficient of weight of the hammer reveals that
increase in weight decreases the Impact strength of zinc aluminium alloy and vice versa.
6. CONCLUSIONS
Work material (97.41%) was found to be significant in ANOVA for Izod Impact Test. Height (2.17%) and Weight
(0.21%) was factors found insignificant for Izod impact test. Work material (97.41%) was found to the most significant
factor and Weight (0.21%) was found least significant factor of Izod impact test. Main effect plot for Izod impact value
shows maximum impact value for ZA-27 alloy and minimum value for ZA-8 alloy. Since Larger the S/N ratio,
optimum is the process parameters. Work Material (A), Weight (B) and Height (C) i.e., A3B2C3. Change in weight and
height has no significant effect on the impact value of Izod impact test.
Work material (93.86%) was found to be significant in ANOVA for Izod Impact Test. Height (6.09%) and Weight
(0.02%) was factors found insignificant for Charpy impact test. Work material (93.86%) was found to the most
significant factor and Weight (0.02%) was found least significant factor of Izod impact test. Main effect plot for Izod
impact value shows maximum impact value for ZA-27 alloy and minimum value for ZA-8 alloy. Since Larger the S/N
ratio, optimum is the process parameters. Work Material (A), Weight (B) and Height (C) i.e., A3B3C2. Change in
weight and height has no significant effect on the impact value of Izod impact test.
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IPASJ International Journal of Mechanical Engineering (IIJME)

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

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

Volume 4, Issue 1, January 2016