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CHAPTER 5

TAGUCHI EXPERIMENTAL DESIGN

5.1 INTRODUCTION

The Taguchi method involves reducing the variation in a process

through robust design of experiments. The overall objective of the method is
to produce high quality product at low cost to the manufacturer. The Taguchi
method was developed by Genichi Taguchi. He developed a method for
designing experiments to investigate how different parameters affect the
mean and variance of a process performance characteristic that defines how
well the process is functioning. The experimental design proposed by Taguchi
involves using orthogonal arrays to organize the parameters affecting the
process and the levels at which they should be varied. Instead of having to
test all possible combinations like the factorial design, the Taguchi method
tests pairs of combinations. This allows for the collection of the necessary
data to determine which factors most affect the product quality with a
minimum amount of experimentation, thus saving time and resources. The
Taguchi method is best used when there is an intermediate number of
variables (3 to 50), few interactions between variables, and when only a few
variables contribute significantly.

5.2 DESIGN OF EXPERIMENT

Classical experimental design methods are too complex and are not
easy to use. A large number of experiments have to be carried out when the
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number of process parameters increase. To solve this problem, the Taguchi

method uses a special design of orthogonal arrays to study the entire
parameter space with only a small number of experiments. Three superplastic
forming parameters are considered as controlling factors. They are Pressure,
Temperature and Time. Each parameter has three levels namely low,
medium and high, denoted by 1, 2 and 3 respectively. According to the
Taguchi method, if three parameters and 3 levels for each parameters L9
orthogonal array should be employed for the experimentation. Table 5.1
shows the Superplastic forming parameters and their levels considered for the
experimentation.

Table 5.1 Process parameters and levels

Levels
Process parameters
Level 1 Level 2 Level 3
Pressure (MPa) A 0.2 0.4 0.6
Temperature (0C) - B 560 580 600
Time (minutes) - C 15 30 45

Orthogonal arrays are special standard experimental design that

requires only a small number of experimental trials to find the main factors
effects on output. Before selecting an orthogonal array, the minimum number
of experiments to be conducted is to be fixed based on the formula below
N Taguchi = 1+ NV (L 1)
N Taguchi = Number of experiments to be conducted
NV = Number of parameters
L = Number of levels
In this work
NV = 3 and L = 3, Hence
N Taguchi = 1+ 4 (3-1) = 9
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Hence at least 9 experiments are to be conducted. Based on this

orthogonal array (OA) is to be selected which has at least 9 rows i.e.,9
experimental runs.

The following standard orthogonal arrays are commonly used to

design experiments:

2-Level Arrays: L4, L8, L12, L16, L32

3-Level Arrays: L9, L18, L27
4-Level Arrays: L16, L32

In this work L9 is sufficient. It would require a total of 27

experiments to optimize the parameters. Taguchi experimental design of
experiments suggests L9 orthogonal array, where 9 experiments are sufficient
to optimize the parameters. Based on main factor, the variables are assigned
at columns, as stipulated by orthogonal array. The last column can be kept
dummy, but no row should be left out. Once the orthogonal array is selected,
the experiments are selected as per the level combinations. It is important that
all experiments are conducted. The performance parameter (output) is noted
for each experimental run for analysis.

5.3 S/N Ratio

In Taguchis design method the design parameters (factors that can

be controlled by designers) and noise factors (factors that cannot be
controlled by designers, such as environmental factors) are considered
influential on the product quality. The Signal to Noise (S/N) ratio is used in
this analysis which takes both the mean and the variability of the
experimental result into account. The S/N ratio depends on the quality
characteristics of the product/process to be optimized. Usually, there are three
categories of the performance characteristics in the analysis of the S/N ratio;
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that is, the lower-the-better, the higher-the-better, and the nominal-the-better.

The S/N ratio for each response is computed differently based on the category
of the performance characteristics and hence regardless of the category the
larger S/N ratio corresponds to a better performance characteristic. In the
present study the dome height and thinning factor are the-higher-the-better
performance characteristics. Once all of the S/N ratios have been computed
for each run of an experiment, Taguchi advocates a graphical approach to
analyze the data. In the graphical approach, the S/N ratios and average
responses are plotted for each factor against each of its levels. From the
graphs, higher the better the values were selected and the confirmation tests
were conducted.

5.4 PROCESS PARAMETERS

SUPERPLASTIC FORMING

PROCESS
RESPONSES
PARAMETERS

PRESSURE
(0.2 MPa, 0.4 MPa DOME HEIGHT
&0.6 MPa)

TEMPERATURE
(560 C, 580 C & THINNING FACTOR
600 C)

TIME
(15 Min, 30 Min
& 45 Min)

Figure 5.1 Process parameters and Responses

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The different process parameters and the responses for the

superplastic forming was shown in Figure 5.1. The effect of process
parameters were discussed below.

5.4.1 Effect of Temperature

Tong et al conducted superplastic forming in Al-4.4Cu-1.5Mg/SiCw

composites. Maximum elongation of 440% was obtained at 523 C . Further
increase in temperature causes the ductility drop rapidly because of the
presence of liquid phase at grain /interface boundaries. The literatures show
that the composites were decrease in strength during superplastic forming.
During superplastic forming, liquid phase forms from the second phase in
elevated temperature. The liquid phase forms in grain boundaries and Al/SiCp
inter phases. The occurrence of liquid phase on composites reduces the
strength of Al6063/SiC composites during superplastic deformation and
enhances their ability to achieve large elongation to failure. The requirement
of high temperature is related to the accommodation process. Higher the
temperature the faster the accommodation process and this leads to an
increase in ductility with temperature. A small amount of liquid is likely to be
beneficial for sliding process and related accommodation as suggested by
Mabuchi and Higashi. At higher temperature too much liquid leads to
premature fracture. This is attributed to intergranular decohesion at thick
liquid boundaries. There fore, a liquid phase is required to be very thin both in
order to relax the stress concentrations and to limit decohesion at liquid
boundaries. To obtain thin liquid layer optimum temperature should be
selected.

5.4.2 Effect of Pressure

In this research work pressure has been maintained constant

through out the process. Initially the strain rate was high and strain rates were
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very low at the end of the process. The strain rate sensitivity index (m) varies
based on the variation of pressure. Increase in m value increases the
formability of the material. In biaxial superplastic forming m value
increases with strain rate. At the end of the process the m value decreases
with decrease in strain rate. At high pressure the components were failed. The
pressure to be optimized to get high m value and thereby maximum
superplasticity can be obtained.

5.4.3 Effect of Time

The forming time is closely related with the feasibility of the

process because excessive time of manufacturing may be unacceptable from
an economic, technological and commercial standpoint. In the constant
pressure superplastic forming process the 50% of the dome height was
formed within 10 minutes of time. After the 10 minutes the dome height
increases very slowly. Increase in time will increases the dome height, but the
percentage of increase in height is very low. At high pressure the components
were failed in a very short time. Optimum time period will save the time and
energy during superplastic forming process. The procedure for taguchi
analysis was shown in figure 5.2
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Set performance
characteristics (Dome Height,
Thinning Factor)

Select control factors and their

levels

Choose orthogonal array as Influence of

per number of factor and parameters
levels

Conduct experiments as per

orthogonal array and observe the
change in critical properties

Data Analysis - S/N Ratio

Arrive at optimal level of Analysis of

process parameters variance

Confirmation experiment to
check whether there is
No
improvement

Yes

END

Figure 5.2 Procedure for Taguchi Analysis

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This statistical significance of the factors can be evaluated through

the analysis of variance (ANOVA). A statistical ANOVA is performed to find
the contribution of each factor for attaining the process outcome.

Three process parameters considered for optimization of the study

are

A. Temperature
B. Gas blow pressure,
C. Forming Time

Taguchi Orthogonal Array Design - L9 (3*3)

Table 5.1 shows the taguchi orthogonal array selector which

shows the orthogonal array for the parameters and levels. For three
parameters and three levels L9 orthogonal array was selected from the
array selector.

Table 5.1 Array Selector

PARAMETERS
2 3 4 5 6 7 8 9 10 11 12
L
2 L4 L4 L8 L8 L8 L8 L12 L12 L12 L12 L16
E
V 3 L9 L9 L9 L18 L18 L18 L18 L27 L27 L27 L27
E
L 4 L16 L16 L16 L16 L32 L32 L32 L32 L32
S 5 L25 L25 L25 L25 L25 L50 L50 L50 L50 L50 L50
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Table 5.2 Levels of process parameters used Taguchi L9 Orthogonal

Array

Experiment Levels
Number A B C
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2

Table 5.3 Experimental design using orthogonal array

Levels
Experiment Pressure
No. Temperature (0C) Time (min)
(MPa)
1 0.2 560 15
2 0.2 580 30
3 0.2 600 45
4 0.4 560 30
5 0.4 580 45
6 0.4 600 15
7 0.6 560 45
8 0.6 580 15
9 0.6 600 30
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The specimens were formed in an open die in accordance with

Table 5.2 and height of the formed component was measured. Experimental
data hence measured is as a shown in table 5.3. Taguchi method of
optimization involves finding out Signal-to-Noise ratio (S/N) in order to
minimize quality characteristic variation due to uncontrollable parameter.
Dome height belongs to larger the better quality characteristics.

5.6 SUMMARY

Design of Experiments was done by Taguchis technique. For three

parameters and three levels L9 orthogonal array was selected. Through pilot
study experiments the levels of parameters were selected. These experiments
were conducted between 520 C and 600 C temperature and 0.2 MPa to 0.7
MPa pressure. From the pilot study the selected levels of temperature were
560 C, 580 C and 600 C.The pressures were 0.2 MPa, 0.4 MPa and 0.6 MPa.
Dome height and thinning factor were the two response variables. Totally
nine experiments were conducted and S/N ratios for dome height and
thinning factor were plotted. Confirmation tests were conducted using
the higher the better values for dome height and thinning factor. The
influence of parameters was found by ANOVA technique.