Application of taugchi method for optimization of dry sliding wear process parameters in improving the wear of al6061+4%b4 c+4%cu based composite

Kumar Vikas, Singh Shailesh, International Journal of Advance Research, Ideas and Innovations in Technology.
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Application of Taugchi method for Optimization of Dry Sliding
wear Process Parameters in Improving the Wear of
Al6061+4%B4C+4%CU based Composite
Vikas Kumar
Mechanical Engineering
Dr. APJ Abdul Kalam Technical University, Lucknow
012vikaskumar@gmail.com
Shailesh Singh
Mechanical Engineering
Dr. APJ Abdul Kalam Technical University, Lucknow
mechshaileshsingh@gmail.com
Abstract: The process parameters can be improved by using Taugchi’s method which is a statistical method of optimization and
it also improve the product quality that is manufactured. The main aim of the current research is to apply Taughci method of
optimization and ANOVA in the optimization of dry sliding wear process parameters of Al6061- 4% B4C & 4% Cu based
composite. In current analysis three factors mainly selected for wear optimization and they are loads, sliding speed, sliding
distance and effect of these parameters are studies and the optimum value of each factor is find out by using the method of
optimization. To study the wear behavior of composite orthogonal array ( L9 ), Signal to nose ratio analysis of variance are used.
The experiment is carried out by using suitable orthogonal array ( L9 ). Experiments are performed on a pin on disc machine
according to the selected orthogonal array. The optimum value of the parameters obtained graphically and confirmation of
experiments are carried out. Smaller is the better approach used for selection of optimum parameters finally scanning of wearied
surfaces under Scanning Electron Microscope and shows the uniform distribution of metal matrix in AMCs.
Keyword: Stir casting, AMCs, Taugchi Method, Orthogonal Array, ANOVA, Dry Sliding Wear, S/N Ratio, Pin on Disc.
I. INTRODUCTION
Metal matrix composite mainly consists of two phase one of them is known as metal matrix phase and other is known as
reinforcement phase. The strength and hardness of metal matrix composite are high when compared with base metal at a reduced
weight. Al6061- 4% B4C & 4% Cu based composite fabricated by stir casting method which is very simple and cost involved in
stir casting is not high. Due to good toughness and good tribological properties metal matrix composite are used in automotive and
aerospace industry and there uses increases day by day.
N. NATARANJAN studied the wear behavior of AMCs uses sliding speed and load are mainly two process parameters and found
that as the metal matrix composite manufactured by stir casting and Taugchi method applied then as the load increases the wear
decrease, with an increase in sliding distance wear increases.[1]. The effect of load and temperature considered by Straffelini et al.
that when the temperature increases above 1500°c and when load also increases both parameters increase the load. [2]. K.S. Sridhar
Raja investigates the wear rate behavior as a function of load and sliding distance of al356 reinforced with boron carbide and he
found that when load increases the also increase but when reinforcement is done above 9% then with increases in load and sliding
distance wear rate decreases considerably.[3]. TR Hemant kumar studied the wear behavior of AL-Cu-Mg alloy and found that on
the addition of cu mg in al alloy the wear resistance increased and he successfully optimizes the wear parameters on a pin on disc
machine and shows the effect of sliding distance, load, sliding velocity and all result graphically.[4]. Veerbhadarappa develop the
composite by stir casting method and varied the percentage of Sic in MMC after performed test on Pin on Disc machine and study
the effect of these variation on wear properties and found that on increase the % of Sic in AMCs the wear decreases but it has
minimum value when sic % has around 6% and when increase the value beyond 6% the wear again increased. He also studied the
effect of normal pressure and sliding distance ant found that on increasing the normal pressure wear decreased and when sliding
distance increased wear also increases.[5]. A DHINAKAR investigates the dry sliding wear properties of Mg group composite and
performed Gray analysis and ANOVA confirms the experiment.[6].

II. TAUGCHI METHOD
Taugchi method is a statistical method of optimization. It is developed by Taugchi and Konishi. Initially, it had developed for
improving the quality of manufactured goods but now a days it is widely used different other fields such as Engineering,
Biotechnology. To obtain the better result the parameters which are to be optimized should be selected carefully and bifurcating
them into control and noise factors. Taugchi method involves identification of proper control factors to obtain the optimum result
of the process. Design of experiment is one of the important and powerful statistical techniques through which the effect of multiple
variables simultaneously can be studied and it uses a series of steps that must follow in a certain sequence for the experiment to
obtain an improved understanding of process parameters. All designed experiments need a certain number of combinations of factors
and levels that are to be tested in order to obtain the result of those conditions. Taguchi method based on the assignment of factors
in the orthogonal array to find out those test condition. DOE process includes mainly three phases they are 1. Planning phase,2.
Conducting phase 3.The analyzing phase. Experimental result analysis uses S/N ratio in order to obtain best process design. Nominal
the best, larger the better, smaller the better is the three categories of performance characteristics to analyze the S/N ratio.
Smaller is the better is mainly uses by a researcher in order to study the dry sliding wear behavior of composite.
Taugchi method mainly involves 8 steps and they are given blow:
1. Identification of the main function and its effects
2. Identification of noise factors, testing condition, and quality characteristics.
3. Identification of objective function which is to be optimized.
4. Identification of control factors and their levels.
5. Selection of orthogonal array and construction of array.
6. Perform the matrix experiments.
7. Study the data, obtain the optimum control factor levels and their performance.
8. Perform the verification experiment.
III. MATERIAL USED AND FABRICATION METHOD
In the present research aluminum which available commercially, boron carbide (size of particle 100mesh), and Cu with 4% of both.
Stir casting used for casting of cylindrical specimens. A different test is performed on specimens after machining of the object in
correct dimensions and mechanical properties are obtained.
ALUMINIUM 6061
Table 1: Typical composition of aluminum alloy 6061
Component Amount % weight
Aluminum Balance
Magnesium 0.8-1.2
Silicon 0.4-0.8
Iron Max 0.7
Cu 0.15-0.40
Zinc Max0.25
Titanium Max 0.15
Manganese Max 0.15
Chromium 0.04-0.35
BORON CARBIDE
Boron carbide powder (see figure 1) is mainly produced by reacting carbon with B2O3 in an electric arc furnace, through carbo
thermal reduction or by gas phase reactions. For commercial use, B4C powders usually need to be milled and purified to remove
metallic impurities.
Table 2: Typical properties of boron carbide
Density (g.cm-3) 2.52
Melting point 2445
Hardness( Knoop 100g) (kg.mm-2
) 2980-3580
Fracture Toughness(MPa.m-1/2
) 2.9-3.7
Young Modulus 450-470
Electrical conductivity 140
Thermal conductivity 30-42

COPPER POWDER
CU possesses very good mechanical properties so it can be used for various applications and AMC’s also.pure Cu is very soft and
very difficult to machine so widely used for alloying and MMC’s.
Table 3: Properties of Cu
Density (g.cm-3) 8.89
Modulus of Elasticity GPa 100-150
Tensile strength MPa 220-345
Coefficient of thermal Expansion 17
Thermal conductivity 300
STIR CASTING
Al 6061 select as base metal matrix and 4% B4C (size of the particle is 100 meshes) and 4% Cu powder used as the reinforced
material. Stir casting used as the fabrication method of metal matrix composite. This method of fabrication is very fast ant the cost
involved in it very low and a uniform mixing obtained. In this method, Al 6061 heated in a muffle furnace and the temp is 750°C
and it is controlled by a temperature controller and at this temperature 4% B4C (size of the particle is 100 mesh) and 4% Cu powder
mixed in melted base metal. To obtain the correct mixing the stirrr rotated in the crucible for about 20 min. at speed 300 rpm. After
20 min. the stirr stopped and molten metal which is a mixture of AMCs is poured in a graphite mould and allow solidifying.
IV. TESTING OF SPECIMENS
To obtain dry sliding wear of Al6061- 4% B4C & 4% Cu based composite wear test was performed on a pin on disc machine. Pin
material is AMC’s composite whose wear is to be finding out and Steel grade EN 32 use as disc material. Disc rotated as per rpm
set in the planning phase and the pin is held stationary and the load is applied through lever mechanism. Wear test were performed
according to the orthogonal array. Wear rate of the specimens is the function of applied load, sliding distance, sliding velocity. The
test procedures are given below:
Initially, pin is fixed in the clamp and then require rpm is set on friction and wear monitoring test rig attached to pin on disc machine
and to achieve a correct value of sliding distance the time set on a timer and all setting done on no loading condition and then load
is applied through lever mechanism. After that machine is started according to set rpm and time after the completion of a time
machine. of is stopped. The final weight of specimen is noted on weighing machine. The difference between initial weight and final
weight gives the weight loose which is measure wear.
V. RESULT AND OPTIMIZATION OF WEAR BY TAUGHCI’S METHOD
Identification of the main function:
Optimization of dry sliding wear of Al6061- 4% B4C & 4% Cu based composite done on pin-on-disc type friction and wear
monitoring test rig.
1. Identification of test condition:
Work material: Al6061+ 4% B4C & 4% Cu.
Machine used: Pin-on-disc type friction and wear monitoring testing.
Counter body material: It is the surface against which pin rotated and it is made of steel grade EN 32.
2. Objective function:
‘Smaller is Better’ approach is selected and S/N ratio is calculated. The formula used for calculation of S/N ratio is given below:
Signal to noise ratio = -10 x(log 1
𝑛
∑ 𝑦𝑖
2𝑛
𝑖=1 )
n= no. of observation, y= wear rate ( mm3
/m)
3. Selection of control factor and their levels
A meeting with the group of people and following the guidelines are given in operator manual provided by the manufacture of
pin-on-disc type friction and wear monitoring test rig is called Brain Storming.
Table4: Shows the Control Factor and Their Levels
Control factors levels
1 2 3
Load (N) 15 30 45
Sliding Velocity (m/s) 2 2.5 3
Sliding Distance (m) 600 1200 1800

4. Orthogonal array:
The l9 orthogonal array used for conducting the experiments in best possible way. The degree of freedom is given below:
DOF: 1 for mean value
8= (2*4), two each remaining factors
Total DOF=9
Table 5: Shows the Orthogonal Array for Conducting the Experiments
Experiment no. levels
1 2 3
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 3
5 2 2 1
6 2 3 2
7 3 1 2
8 3 2 3
9 3 3 1
Table 6: Shows the Wear Rate of Specimens According To Experiments Conduct On Pin On Disc Machine
Experiments no. S/N Ratio
Wear rate
1 59.5424
2 61.7010
3 56.7804
4 54.3866
5 53.1888
6 54.9771
7 51.1785
8 52.8352
9 49.2621
VI. OPTIMIZATION OF WEAR AND SELECTION OF OPTIMUM PARAMETERS
1. S/N ratio of individual control factors are given below:
SL1 = (S/N1+ S/N2+ S/N3), SL1 = (S/N4+ S/N5+ S/N6), SL1 = (S/N7+ S/N8+S/N9),
SV1 = (S/N1+ S/N4+ S/N7), SV2 = (S/N2+ S/N5+ S/N8), SV3 = (S/N3+ S/N6+ S/N9),
SD1 = (S/N1+ S/N5+ S/N9), SD2 = (S/N2+ S/N6+ S/N7), SD3 = (S/N3+ S/N4+ S/N8)
S/Nk represents the S/N ratio corresponding to kth
experiments.
Average S/N ratio can be easily calculated and Table 7: shows the average S/N for each factor
Levels Load Sliding Velocity Sliding Distance
Avg. S/N ratio Avg. S/N ratio Avg. S/N ratio
1 58.3413 55.0358 52.8991
2 54.7865 56.9083 55.9522
3 51.0919 53.6732 54.6674

THE GRAPHICAL REPRESENTATION OF THE ABOVE VALUES OF S/N RATIOS IS GIVEN BELOW:
1. LOAD VS. AVG. S/N RATIO GRAPH
2. SLIDING VELOCITY VS. AVG. S/N RATIO GRAPH
46
48
50
52
54
56
58
60
15 30 45
Avg.S/NRatio
Load(N)
Load vs. Avg.S/N Ratio
Graph
Avg. S/N Ratio
52
53
54
55
56
57
58
2 2.5 3
Avg.S/NRatio
Sliding Velocity
Sliding Velocity vs. Avg. S/N Ratio
Graph
Avg. S/N Ratio
51
52
53
54
55
56
57
600 1200 1800
Avg.S/NRatio
Sliding Distance
Sliding Distance vs. Avg. S/N Ratio
Graph
Avg. S/N Ratio

SLIDING DISTANCE VS. AVG. S/N RATIO GRAPH.
From the above graph, we can conclude the optimum value of the parameters and their levels. The optimum values of the
parameters are given below:
Selected parameters Optimum values
Load 45N
Sliding velocity 3 m/sec
Sliding distance 600 meters
VII. ANALYSIS OF VARIANCE AND CONFERMATION OF EXPERIMENTS
Response magnitude in the percentage of each factor in the orthogonal array can be easily evaluated with help of Analysis of
variance. Analysis of variance involves a statistical method on the variation of group causes. We can relate this technique with the
design of experiments. ANOVA total sum of square is equal to the sum of the square of deviations and the error component. In
ANOVA we construct a table and valve of F (test statics) is calculated and compare this valve with Ftab.
If the value of Fcal< Ftab. then the null hypothesis is selected and its variation can be attributed to chance. If the opposite of the earlier
condition occurs, this will lead rejection of the hypothesis.
Table 8: SHOWS THE ANOVA TABLE
Source of
variation
Degree of
freedom
Sum of
squares
Mean square Fcal Ftab P value
treatments 2 3.7259 1.86295 0.4575 5.48 0.234
Error 6 24.5162 4.086
Total 8
From the above ANOVA table, it is concluded that Fcal < Ftab. so above hypothesis are selected and experiments have some common
causes of variation this also validates the above Taugchi’s method optimize the parameters successfully.
TABLE 9: THE % CONTRIBUTION OF EACH FACTOR IN DRY SLIDING WEAR
Parameters % Contribution in dry sliding wear
Load 72.46
Sliding velocity 19.29
Sliding distance 7.23
Error 1.02
From the above table, we can conclude that load is the parameter which affects the dry sliding wear of a composite. Sliding distance
and sliding velocity also affect the dry sliding wear but very less than load affects.
CONLUSION
 Stir casting method successfully apply for fabrication of composite and it has very low cost and it produced the uniform
mixing and homogenous microstructure.
 Experiments are carried out according to the orthogonal array on a pin on disc machine with selected parameters.
 Taugchi’s method provides the optimum values of wear rate of a composite with help of experiments.
 Wear rate mainly depends upon load, sliding distance, sliding velocity but in current research load is the main factor which
contributes the wear and has higher % of dry sliding wear rate contribution.
 As the load increased the wear rate of AMCs decreased and has an optimum value at 45N.
 As sliding speed increased the wear rate also decreased but when sliding distance increased the wear is also increased
slowly.
 ANOVA successfully applies which gives the validation of experiments and confirmation of experiments is also carried
out.
 The developed AMCs have a good tensile strength, high hardness, low weight and good impact energy.
It can be used for high speed application in which parts are subjected a very high degree of dry sliding wear such as automotive
industry and aerospace industries in pistons, bearings, brake rotor, cylinder heads etc.

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Application of taugchi method for optimization of dry sliding wear process parameters in improving the wear of al6061+4%b4 c+4%cu based composite

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