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A=
x x
x x
Where u is the number of trails and v is the number of responses, A is an array of responses.
Trails
1
2
3
4
5
6
7
8
9
Open
Voltage
(A)
1
1
1
2
2
2
3
3
3
Servo
Voltage
(B)
1
2
3
1
2
3
1
2
3
Wire Feed
(C)
1
2
3
2
3
1
3
1
2
Material Removal
Rate (MRR)
(mm3/min)
78.9600
62.8800
55.1200
79.6000
65.9200
51.2000
75.6000
58.3200
49.2800
Machining Time
(MT) (min)
Gap Voltage
(GV) (Volts)
5.2160
6.4500
7.3170
5.1170
6.1670
7.9000
5.4000
6.9500
8.2170
30.3400
38.9600
48.5200
30.2000
37.8400
50.6900
30.5200
42.1200
51.2300
1
(S/N)LB = -10log10[ v x
u=1
(1)
For Higher-is-better (HB),
v
1
1
(S/N)HB = -10log10[ v x ]
u=1
(2)
Max ( x ) x
Max ( x ) Min ( x )
(3)
Z=
x Min ( x )
Max ( x ) Min ( x )
(4)
Where Z is the normalised value for xuv responses, Min (xuv) is the smaller value of xuv and Max (xuv) is the
larger value of xuv, Z is a normalized array.
Z=
Trails
S/N (MRR)
(dB)
37.9481
35.9702
34.8262
38.0183
36.3803
34.1854
37.5704
35.3163
33.8534
1
2
3
4
5
6
7
8
9
S/N (MT)
(dB)
-14.3467
-16.1912
-17.2867
-14.1803
-15.8015
-17.9525
-14.6479
-16.8397
-18.2943
TOTAL
MEAN
VARIANCE
COVARIANCE
CORRELATION
X-X'
Y-Y'
Z-Z'
0.466
0.443
4
0.488
9
0.015
7
0.983
2
0.040
5
0.001
2
0.508
3
0.488
8
0.474
4
0.233
6
0.755
1
0.889
7
0.482
8
0.606
7
0.394
1
0.419
2
0.089
5
0.079
7
0.916
9
0.892
5
0.113
6
0.012
4
0.351
3
0.646
4
0.622
0.992
5
4.655
3
0.517
2
4.355
4
0.483
9
4.411
4
0.490
1
0.008
9
0.283
6
S/N (GV)
(dB)
-29.6403
-31.8124
-33.7184
-29.6001
-31.5590
-34.0984
-29.6917
-32.4898
-34.1905
0.9832
0.5083
0.2336
1.0000
0.6067
0.0797
0.8925
0.3513
0.0000
Z=
z z
z z
0.004
9
Normalized
(MRR)
0.9832
0.5083
0.2336
1.0000
0.6067
0.0797
0.8925
0.3513
0.0000
0.0405
0.4888
0.7551
0.0000
0.3941
0.9169
0.1136
0.6464
1.0000
Normalize
d (GV)
0.0012
0.4744
0.8897
0.0000
0.4192
1.0000
0.0124
0.6220
0.9925
0.0012
0.4744
0.8897
0.0000
0.4192
1.0000
0.0124
0.6220
0.9925
(X-X')(XX')
(Y-Y')(YY')
(Z-Z')(ZZ')
(X-X')(YY')
(Y-Y')(ZZ')
(X-X')(Z-Z')
0.217156
0.1966035
6
0.2390232
1
-0.2066244
0.21677826
-0.2278274
0.000079
0.000024
0.0002464
9
-0.000044
-0.000077
0.00013973
0.0804289
6
0.0735494
4
0.1596801
6
0.10837152
-0.11332656
0.2330958
4
0.2341592
1
0.2401980
1
0.23715939
-0.23662028
0.0080102
5
0.0080640
4
0.0050268
1
-0.0080371
0.00636682
-0.00634555
-0.1894375
0.2207867
-0.22308125
0.17689231
-0.17928081
0.02143375
-0.02188221
0.25928864
-0.25984128
-1.1475415
1.24700039
-1.26806561
-0.1434
0.1559
-0.1585
0.271
2
0.399
6
0.483
9
0.089
8
0.490
1
0.070
9
0.437
5
0.433
0.509
9
0.1914062
5
0.187489
0.2599980
1
0.375
3
0.370
3
0.477
7
0.1408500
9
0.1371220
9
0.2281972
9
0.162
5
0.131
9
0.0275228
1
0.0264062
5
0.0173976
1
0.516
1
0.502
4
0.2674958
4
0.2663592
1
0.2524057
6
1.1660450
4
1.1297768
1.4021733
5
0.1458
0.1412
0.1753
0.165
9
0.517
2
Normalized
(MT)
0.0405
0.4888
0.7551
0.0000
0.3941
0.9169
0.1136
0.6464
1.0000
0.0769123
2
0.2336269
2
0.1389735
9
0.0269587
5
0.2669269
2
-0.9997
0.9907
-0.9917
B=
N N
N N
]
Cov(x ( u ) , x (v))
Nu,v=
Var ( x ( u ))Var ( x ( v ) )
(5)
Where u=1, 2,3..v, and Cov(x(u), x(v)) is the covariance of x(u) and x(v).
Step 5 Calculate the Eigen values and Eigen vectors with the help of correlation coefficient,
(R-xIu)Vuv=0
(6)
x V
PC=
u=1
(7)
Where i=1,2,3.n
Step 7 Calculate the Total Principal Component Index,
v
TPCI =
PC e (x)
x=1
(8)
eig( x )
Where, e(x) =
eig(x)
x=1
Level 1
m1
n1
o1
Level 2
m2
n2
o2
m1 =
Level 3
m3
n3
o3
n1 =
o1 =
Carbon (C)
0.66
Iron (Fe)
95.60
(b)
(a
Figure 2. Top view (a) and side view (b) of En45A Alloy steel material
1.2. Table of input parameters
S. No
1.
2.
3.
Variables
Open Voltage (OV)
Servo Voltage (SV)
Wire Feed (WF)
Level (L2)
85
40
6
Level (L3)
90
50
7
This technique is found by Genichi Taguchi, a Japanese scientist which is based on orthogonal array. Nowever
day it is widely using day by day it makes trails compact and make less difficult to find out the optimal
parameters. This technique is totally depends on factors and number of trails (level). Here we consider Open
voltage (OV), Servo voltage (SV), and Wire feed (WF) as an input parameters and applied L 9 Taguchi
orthogonal array [19]. Taguchi L9 orthogonal array is shown in table 3.
Trails
1
2
3
4
5
6
7
8
9
Normalized (GV)
0.0012
0.4744
0.8897
0.0000
0.4192
1.0000
0.0124
0.6220
0.0000
1.0000
0.9925
Eigen Vectors
Eigen Values
Proportion
Cumulative
2.9882
0.9960
0.9960
PC3
0.726
0.687
-0.039
0.0116
0.0040
1.0000
0.0002
0.0000
1.0000
Trails
1
2
3
4
5
6
7
8
9
VPC3
0.7415
0.6863
0.6536
0.7260
0.6949
0.6488
0.7255
0.6748
0.6483
DOF
2
2
2
2
F-values
12.466
7.401
8.151
Contribution (%)
42.96
25.50
28.09
3.45
100
identify optimal process parameters (A2 B1 C2), means on 85 Open Voltage, 30 Servo Voltage and 6 Wire feed,
machining will be optimum it will give maximum MRR at minimum MT and GV which is in table 11.
S. No.
Open Voltage
85
Machining
Time
5.1170
Gap
Voltage
30.2000
Individual optimal process parameters are identified and shown in Table 12. According to this optimal process
parameters are (A3 B1 C2).
Inputs
Open Voltage (OV)
Servo Voltage (SV)
Gap Voltage (GP)
* Optimal values
Rank
3
1
2
4. Conclusions
In this paper Taguchi orthogonal array is coupled with Principal component analysis are used to improve
multiple responses like MRR (material removal rate), MT (machining time), & GV (gap voltage) of En45A
alloy steel for WEDM. As well as our result is compare and tested with the help of ANOVA. The conclusions of
this experimental optimization work as follows:
Experimental results were found with good agreement.
The optimal parameters combination was identified as A 2B1C2 i.e. Open voltage 85V, Servo Voltage 30V
and wire feed 6m/min.
Individual optimal parameter combination was identified as A3B1C2.
The result of ANOVA shows affect of Open voltage is more, than other input parameters.
ANOVA find out the 3.45% of error in experimental calculation.