INTERNATIONAL JOURNAL OF and Technology (IJMET), ISSN 0976 International Journal of Mechanical Engineering MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME AND TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 328-345 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2011): 1.2083 (Calculated by GISI) www.jifactor.com

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IAEME

OPTIMISATION OF SHOCK ABSORBER PARAMETERS USING FAILURE MODE AND EFFECT ANALYSIS AND TAGUCHI METHOD
A.Mariajayaprakash Assistant Professor and Head, Department of Mechanical Engineering, Rajiv Gandhi College of Engineering and Technology, Puducherry, India; e-mail : jayaprakashrgcet@gmail.com Dr.T. SenthilVelan Professor and Head , Department of Mechanical Engineering, Pondicherry Engineering College, Puducherry, India; e-mail: tsenthilvelan@hotmail.com K.P.Vivekananthan Deputy General Manager (manufacturing),TENNECO, Puducherry, India e-mail: vivekkp64@yahoo.com ABSTRACT The various process parameters affecting the quality characteristics of the shock absorber during the process were identified by using the Ishikawa diagram and FMEA. The identified process parameters are: Welding process parameters (squeeze, heat control, wheel speed and air pressure), tamper sealing process parameters(load, hydraulic pressure , air pressure and fixture height),Washing process parameters(total alkalinity, temperature, PH value of rinsing water and timing),Painting process parameters(flowability, coating thickness, pointage and temperature).Out of above mentioned four process parameters welding and tamper sealing process parameters were optimized by using Taguchis method in the earlier work. In this paper, the remaining process parameters namely washing and painting process parameters are optimized by using Taguchis method. Key words: Taguchis method, Ishikawa diagram, ANOVA, FMEA

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LIST OF SYMBOLS r yi DOE A kA required LN N ANOVA M VFactor SS V P e Ve F(, 1, e) eff n CI T Number of tests in a trial Response value of observation in the ith test Design of experiments Degrees of freedom Degrees of freedom for factor A Number of levels for factor A Total degrees of freedom required Total degrees of freedom of the available orthogonal array Number of trials Analysis of variance Overall mean percentage defects Variance of factor Sum of square Expected amount of variation Percent contribution Mean Level of risk Degrees of freedom for the error Error variance F ratio required at the level of risk Effective number of replications Total number of experiments Confidence interval Average values of defects at different levels

1.0 INTRODUCTION Shock absorber is one of the major component used in automobiles. It is used to absorb vibrations when the vehicle is moving. Otherwise that vibrations affect the vehicle and the rider. The defects which are occurred during the process affect the quality of the shock absorber. In order to minimize the defects and improve the quality, the following tools are employed. First, Cause and effect diagram or Ishikawa diagram is used for identifying the parameters that may affect the quality of the shock absorber during the process. Then, Failure Mode Effect Analysis tool is applied to find out the most significant process parameters that may affect the quality of the shock absorber. Finally, Taguchi method is used to optimize the process parameters. Taguchi method is an efficient and powerful tool that can reduce the experimental trails necessary to determine the optimal conditions. It has been widely used in many different fields (Yung-Tien Liu et al., 2010). Tsai et al. (2008) used Taguchi design experiments to identify the optimal abrasive jet polishing parameters when applied to the polishing of electrical discharged machined SKD 61 mold steel specimens. This paper shows that ANOVA provides an indication of

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the significance of the individual control factors. Mahapatra and Vedansh Chaturvedi (2009) proved that Taguchis experimental design is a simple and systematic way of analyzing a complex process with less experimental design. In this paper, test parameters are optimized for minimum wear by using Taguchis method. Ganapathy et al. (2009) optimized the operating parameters in Jatropha bio diesel engine by using Taguchi method. In this paper it is proved that signal to noise ratio is used to optimize the various input parameters of the model. This paper shows that the Taguchi approach based thermodynamic model has improved the performance parameters slightly. Pishbin et al. (2010) investigated the effects of processing parameters, including suspension concentration, pH and electric field by using Taguchis DOE approach in electrophoretic deposition of bio glass suspension. Mojtaba momeni et al. (2010) obtained the optimal condition for DOS measurement based on Double- loop EPR technique in H2 SO4 containing KSCN solution using the Taguchi method. In this paper, it is concluded that higher the S/N ratio, greater is the effect on the DOS measurement. Te-Sheng Li et al. (2009) explained how Taguchi method is utilized for optimizing the parameters in thermal flow techniques for sub-35 nm contact-hole fabrication. In this article, the optimal thermal flow parameter settings are determined by signal to noise ratio and ANOVA analysis. Balamurugan Gopalsamy et al. (2009) applied Taguchi method to find optimum process parameters for end milling while hard machining of hardened steel. Results obtained from Taguchi method closely match with ANOVA and it is found that cutting speed is most influencing parameters corresponding to quality characteristics. Khandoker abul Hossain et al. (2010) illustrated that the cause and effect diagram provides the solution to reduce the emission of co2. Andrejkovic et al. (2011) explained that Ishikawa diagram quickly identify the causes of quality problems. Tlale et al. (2008) applied the usage of cause and effect diagram in cost drivers for manufacturing process. Hu-chen liu et al. (2011) reported about the usage of FMEA tool and how it is applied to identify the failure modes. Arabian-Hoseynabadi et al. (2010) explained that the FMEA tool is applied in wind turbine systems. In this paper, the reliability of the wind turbine system is improved by applying FMEA tool. Boldrin et al. (2009) identified and reduced the risks of failure in ITER NB injector using FMEA tool. . 2.0 CAUSE AND EFFECT DIAGRAM Cause and effect diagram is a tool for identifying the root causes of quality problems. It is also called as Ishikawa diagram or Fishbone diagram ( Ilie and Ciocoiu , 2010).An Ishikawa diagram is constructed as shown in Fig.1. By using this diagram the various process parameters that affect the quality of the shock absorber are identified ( Mohan sen and shan, 2005).The identified process parameters are listed below: 1.Washing parameters 2.Welding parameters 3.Painting parameters 4.Tamper sealing parameters 5.Assembly parameters 6.Lubrication parameter

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7.Inspection and Checking Parameters 8.Dimensioning parameters 9.Polishing parameter 10.Testing parameters

WASHING painting
Improper frequency of change Flowability Coating thickness

Presence of oil/grease

Paint not adhering Rust corrosion

1.wrong parameters
2.improper preparation of solvent

Pointage temperature DEFECTS DEFECTS IN IN SHOCK SHOCK ABSORBR ABSORBR

Cylinder not ball sized

1.Breakage
2.burrs

Setup not correct

Ball sizing

1.concentricity
2.cylinder bend checking Poor surface finish

Cylinder not ball sized

1.Concentricity more
than specification 2.wrong jaws 3.worn out jaws Bad stone condition

. DIMEN SIONING

INSPECTION /CHECKING

POLISHING

Fig.1 Cause and effect diagram 3. FAILURE MODE AND EFFECT ANALYSIS After constructing Ishikawa diagram, it is important to perform Failure Mode Effect Analysis. FMEA is a powerful tool which is used to define, identify and eliminate known potential failures, problems, errors and so on (hu-chen liu et al, 2011).Today, FMEA technique has been applied in many places, such as automobiles, aerospace, military, electricity and mechanical industries. FMEA is conventionally carried out by a team of engineers. By using their knowledge and past data, Risk Priority Number(RPN) value is assigned for each failure component.(Zaifang Zhang and Xuening Chu, 2011). RPN is the product of the occurrence (o), severity(s), and detection (d) of a failure. The three risk factors are evaluated using 10 points scale. Failure modes with higher RPN values are assumed to be more important and are given higher priorities than those with lower RPN values (Ying ming wang et al., 2009). In this paper, washing and painting process parameters are having higher RPN values. Hence these two process parameters are considered as most significant process parameters.

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4. TAGUCHIS METHOD Taguchi method is an efficient tool for acquiring optimal process parameters. In this method, number of experiments are reduced. In this method two important tools are used. i) orthogonal array and ii) Signal to noise ratio ( Cevdet Gologlu and Nazim Sakarya, 2008). First, experiment parameter factors and their levels are selected. In this study, four painting process parameters are used as control factors and each parameter is designed to have three levels ( kilickap, 2010).The selected process parameters, ranges and their levels are shown in Table 1. Table 1 Process parameters with their ranges and values at three levels Parameter designation A B C D Process parameters Flowability ( sec) Coating thickness(microns) pointage Temperature (0C) Range 15-25 20-50 6-12 20-50 Level 1 15 20 6 2 Level 2 20 40 8 35 Level 3 25 50 12 50

4.1. Selection of Orthogonal array An orthogonal array for process design is applied on the knowledge of control factors and levels. The number of experiments can be reduced by using orthogonal array.( yu - tang yen et al.,2010).The degrees of freedom for the orthogonal array should be greater than or at least equal to those for the process parameters. In this study, L9 orthogonal array having 8 degrees of freedom is selected ( Anawa and Olabi, 2008).This orthogonal array has four columns and nine experiments runs and it is shown in Table 2. Table 2 L9 orthogonal array Table 3 Experimental L9 array

Run 1 2 3 4 5 6 7 8 9

A 1 1 1 2 2 2 3 3 3

B 1 2 3 1 2 3 1 2 3

C 1 2 3 2 3 1 3 1 2

D 1 2 3 3 1 2 2 3 1

Trial no.

A Flow ability ( sec) 15 15 15 20 20 20 25 25 25

B Coating thickness (microns) 20 40 50 20 40 50 20 40 50

C pointage 6 8 12 8 12 6 12 6 8

D Temperature (0C) 20 35 50 50 20 35 35 50 20

1 2 3 4 5 6 7 8 9

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4.2. Conducting the Experiment After selecting the orthogonal array, the factors at different levels are assigned for each trial. The assigned experimental array is shown in Table 3.The experiments are conducted using single randomization technique. Each experiment is repeated three times for the same set off parameters.(Ross,1988 ; Hazura Mohamed et.al.,2008).In each trial, the defects occurred are recorded and it is shown in Table 4. In this work, the defects that occur during the welding, washing, painting, and tamper sealing process are considered. The percentage of the defects for each repetition was calculated by using the given formula, and then the average of the defects were determined for each trial condition and it was shown in Table 5. No. of defects occurring due to Painting process Percentage of defects = Total no. of defects occurring in the process (welding, washing, painting and tamper sealing) Table 4 Defects and number of defects occurred during the experiments Defects Trial 1 paint not adhering paint not adhering paint not adhering powder deposit rusting paint not coming paint not coming paint not coming rusting not drying not cleaning 4 1 manual coating not drying not cleaning powder deposit rusting not drying over heating powder deposit over heating 4 2 2 2 2 3 21 No. of defects Trial 2 4 2 4 2 2 2 4 2 24 Trial 3 4 1 4 2 2 2 4 2 23

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Table 5 Painting defects values and signal to noise (S/N) ratios against trail numbers Trial no. 1 2 3 4 5 6 7 8 9 % of defects in experiment 1 4.00 2.67 5.33 1.33 2.67 2.67 2.67 2.67 4.00 2 5.00 2.50 5.00 3.75 2.50 2.50 2.50 3.75 2.50 3 5.19 1.30 5.19 2.60 2.60 2.60 2.60 5.19 2.60 average 4.73 1.71 5.18 2.56 2.59 2.59 2.59 4.31 3.03 S/N ratio -13.55 -7.00 -14.28 -8.77 -8.26 -8.26 -8.26 -12.06 -9.85

4.3. S/N Ratio Taguchi technique utilises the signal to noise ratio(S/N) approach to measure the quality characteristic deviating from the desired value. S/N ratio is used as an objective function for optimizing parameters. (Gunawan Setia Prihandana et.al., 2009).Control factors are easily adjustable and it is set by the manufacturer. These factors are most important in determining the quality characteristics. Noise factors are difficult, impossible, or expensive to control (weather, temperature, humidity etc.). The S/N ratio is the ratio of mean (signal) to the standard deviation (noise). There are several S/N ratios available depending on the type of characteristics ( Mahapatra et.al., 2008 ; Sanjit Moshat et al., 2010).Usually three types of S/N ratio analysis are applicable: 1) smaller is better n = -10 log 1/n yi2 i=1 2) nominal is the best n = -10 log 1/n 2/ 2 i=1 3) higher is better. n = -10 log 1/n 1/yi2 i=1 = S/N ratio, yi = value of quality characteristic at ith setting, = Mean, n= total number of trial runs at ith setting, = standard deviation.

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In this study, in order to minimize the defects, smaller is better S/N ratio is chosen. Smaller is better S/N ratios are computed and the values are recorded in table 5. The main objective of shock absorber process is to minimize the defects by determining optimal level of each factor. Since log is monotone decreasing function, it implies that we should maximize the S/N ratio.(Fang-Jung Shiou and Chih-Cheng Hsu, 2008).The average values of the painting defects and S/N ratios for each parameter at different levels are calculated and are recorded in Table 6. Table 6. Average values of painting defects and S/N ratios at different levels Factors Level 1 Painting S/N defects ratios 4.02 -11.61 3.29 -10.19 3.73 -11.29 3.45 -10.55 Level 2 painting S/N defects ratios 2.58 -8.43 2.87 -9.10 2.58 -8.54 2.45 -7.84 Level 3 painting S/N defects ratios 3.16 -10.06 3.60 -10.80 3.45 -10.27 3.87 -11.70

A B C D

The values given in table 6 are plotted in fig 2 and fig 3 .Fig 2 and fig 3 show the average values of casting defects and S/N ratios for each parameter at different levels. From fig2 and fig.3 it is clear that the casting defects are minimum at the parameter levels A2, B2, C2 and D2 and the S/N ratios are maximum at the same levels of the parameters (A2, B2, C2 and D2.). Since a higher S/N ratio means a better quality characteristic (minimum defects), the optimal combination of control factor levels is therefore determined as A2B2C2D2.

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 Fig 2 Average values of painting process defects for each parameters at different levels
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1 2 3 1 2 3 1 2 3 1 2 3 Fig.3 Average values of S/N ratios for each parameter at different levels 4.4. Analysis of Variance (ANOVA) The purpose of ANOVA is to investigate which process parameters significantly affect the quality characteristic. The total variation may be decomposed into many components.In this paper, the total variation present in the process is decomposed to the following components: 1. variation due to factor A 2. variation due to factor B 3. variation due to factor C 4. variation due to factor D 5. variation due to error The total variation is calculated using the values given in table 4. Total variation SST Variation due to error SSe = SSA +SSB +SSC +SSD +SSe = SST (SSA +SSB +SSC +SSD)

Total degrees of freedom T = (A+ B+ C+ D +e) e = T (A+ B+ C+ D) = 26 (2+2+2+2) = 18

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Table. 7 ANOVA for painting defects and S/N ratios source sum of squares Painting S/N defects ratio 9.44 14.97 2.40 4.20 6.44 11.39 9.63 23.41 9.56 0.60 37.47 54.57 Degrees of freedom Painting S/N defects ratio 2 2 2 2 2 2 2 2 18 2 26 8 variance Painting defects 4.72 1.20 3.22 4.81 0.53 1.44 S/N ratio 7.49 2.10 5.70 11.70 0.30 6.82 F ratio Painting defects 8.90 2.26 6.07 9.07 1.00 S/N ratio 24.87 6.98 18.92 38.89 1.00

A B C D error total

The results of analysis of variance (ANOVA) are shown in table 7. In table 7, it is clear that the parameters A, C and D significantly affect both mean and variation in the painting defects. 5. RESULTS AND DISCUSSIONS 5.1. Percent contribution Percent contribution is the function of the sum of squares of each significant item. Percent contribution to the total sum of square can be used to evaluate the importance of a change in the process parameter on these quality characteristics (Lakshminarayan and Balasubramanian, 2008; Balamurugan Gopalsamy et al.,2009). It is calculated using the formulae given below: Percent contribution (P) = (SSA / SST) *100 SSA = SSA (e) (A) VA = VA+ V error where VA is the expected amount of variation due solely to factor A given below: VA = SSA / A VA = SSA / A

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Table 8 ANOVA for painting defects, including percent contribution Sum of squares 9.44 2.40 6.44 9.63 9.56 37.47 Degrees of freedom 2 2 2 2 18 26 Expected SS' 6.94 Percent contribution (P) 18.52

source A B C D error (pooled) total

Variance 4.72 1.20 3.22 4.81 0.53 1.44

F ratio 8.90 Pooled (2.6) 6.07 9.07 1.00

6.44 9.63 14.46 37.47

17.19 25.69 38.60 100.00

Table 9 S/N ratios for painting defects, including percent contribution sum of squares 14.97 4.20 11.39 23.41 0.6 54.57 Degrees of freedom 2 2 2 2 8 Expected Percent SS' contribution(P) 12.72 9.68 19.89 12.29 54.57 23.31 17.73 36.44 22.52 100.00

source

Variance

F ratio

A B C D error (pooled) Total

7.49 5.70 11.70 0.30 6.82

24.87 18.92 38.89 1.00

The percentage of contribution of flowability, , pointage, and temperature is shown in table 8. 5.2. Estimating the mean From table 8, it is clear that factor B has the least effect on the quality characteristic. In order to prevent over estimation, factor B is not considered and the estimation of mean for painting defects is calculated by the following equation: (Te sheng Li et al., 2009) =T+ (A2-T) + (C2-T) + (D2-T) where T is the average values of painting defects at different levels. The mean for a selected trial condition for parameters at (A2,B2,C2,D2) is 1.11. 5.2.1. Confidence Interval around the estimated mean An important step in Taguchis optimization technique is to conduct confirmation experiments for validating the predicted values. Thus a 95% confidence interval (CI) for

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the predicted mean of optimum quality characteristic on a confirmation test is estimated using the following two equations : (Horng Wen Wu and Hui Wen Gu, 2010). CI3 = [ F( , 1, e) Ve (1/ eff +1/r)]1/2 eff = N/ (1+ total DOF associated in the estimate of mean ) where is the level of risk, Ve is the error variance, e is the degrees of freedom for the error, eff is the effective number of replications and r is number of test trials. Using the values in Table 5, the CI was calculated as follows eff = N/ 1+ (total DOF associated in the estimate of mean ) = 27/ (1+2) = 9 = 1- confidence limits ( 95%) = 0.05 F ratio = (1, 0.05, 18) = 4.41 (tabulated) Confidence Interval CI3 = 1.02 The 95% confidence interval of the predicted optimum of the shock absorber defect is: 0.09<1.02< 2.13. 5.3. Confirmation experiments Three confirmation experiments were conducted at the optimum setting of the process parameters. The flowability was set at the second level (A2), coating thickness at the second level (B2), Wheel speed at the second level (C2) and Air pressure was kept at the second level (D2). The average of the respondents defects in each experiment is found to be 1.22%; the result was within the CI of the protected optimum of the casting defects. The confirming experiments results gave 1.22% < 2.13 % (maximum of CI). Therefore, the selected parameters as well as their appropriate levels are significant enough to obtain the desired result. 5.3.1. Result of the analysis The Shock Absorber experiments has been conducted, ANOVA is carried out using the results of experiments and then the interpretation methods are used to obtain the percent contribution of each parameter and optimum levels of each parameter: 1. The percent contribution of each parameter to the variation of painting defects and optimum parameter (under economic condition) shown in Table 8. 2. The optimum levels of various parameters for minimum painting defects of shock absorber are shown in Table 9. 3. The predicted range of optimum painting defects is 0.09<1.02< 2.13.

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Table 10

Optimum parameters under economic considerations Parameter Flowability (sec) Coating thickness (microns) pointage Temperature (o C) Optimum levels 2 2 2 2 Optimum value 20 40 8 35

Parameter designation A B C D

In the same manner calculations are carried out and optimum values are found for washing process. Table 11 Process parameters with their ranges and values at three levels Parameter designation A B C D Process parameters Total Alkalinity (g/lit.) Temperature(oC) Rinsing water (PH) Timing (min) Range 40-80 45-75 5.5 -8.5 0-25 Level 1 40 45 5.5 5 Level 2 70 60 6.5 15 Level 3 80 75 8.5 25

Table 12 Defects and number of defects occurred during the experiments

Defects oil presence oil presence oil presence oil presence oil presence oil presence over heated over heated over heated more time taken oil presence More time taken over heated over heated powder deposited more time taken more time taken defects number 3 1 2 1 1 1 1 1 1 12 2 2 2 2 1 1 1 1 3 15 3 1 2 1 1 1 1 2 2 14

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Table 13 washing defects values and signal to noise (S/N) ratios against trail numbers
Trial no. 1 2 3 4 5 6 7 8 9 1 4.00 1.33 2.67 1.33 1.33 1.33 1.33 1.33 1.33 % of defects in experiment 2 2.50 2.50 2.50 2.50 1.25 1.25 1.25 1.25 3.75 3 3.90 1.30 2.60 1.30 1.30 1.30 1.30 2.60 2.60 average 3.47 1.71 2.59 1.71 1.29 1.29 1.29 1.73 2.56 S/N ratio -10.96 -5.10 -8.27 -5.10 -2.24 -2.24 -2.24 -5.27 -8.77

Table 14 Average values of washing process defects and S/N ratios at different levels Factors Level 1 washing S/N defects ratios 2.59 -8.11 2.16 -6.10 2.16 -6.16 2.44 -7.32 Level 2 washing S/N ratios defects 1.43 -3.19 1.58 -4.20 2.00 -6.32 1.43 -3.19 Level 3 washing S/N defects ratios 1.86 -5.43 2.15 -6.43 1.73 -4.25 2.00 -6.21

A B C D

Table 15 ANOVA for washing process defects and S/N ratios source sum of squares washing defects A B C D error total 6.14 1.98 0.87 4.59 7.36 20.95 S/N ratio 36.25 8.54 7.85 27.30 0.32 108.23 Degrees of freedom washing defects 2 2 2 2 18 26 S/N ratio 2 2 2 2 2 8 Variance washing defects 3.07 0.99 0.44 2.30 0.41 S/N ratio 18.13 4.27 3.93 13.65 0.16 13.53 F ratio washing defects 7.51 2.42 1.07 5.62 1.00 S/N ratio 112.84 26.58 24.45 84.97 1.00

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Table 16 ANOVA for washing process defects, including percent contribution sum of squares 6.14 1.98 0.87 4.59 7.36 20.95 Degrees Expected Percent of Variance F ratio SS' contribution(P) freedom 2 3.07 7.51 5.32 25.40 2 0.99 pooled(2.42) 2 0.44 pooled(1.06) 2 2.30 5.62 3.78 18.02 18 26 0.41 1.00 11.85 20.95 56.58 100.00

source A B C D error (pooled) total

Table 17 S/N ratios for washing process defects, including percent contribution sum of squares 36.25 8.54 7.85 27.30 0.32 108.23 Degrees of freedom 2.00 2.00 2.00 2.00 8.00 Expected Percent SS' contribution(P) 35.93 8.22 26.98 37.10 108.23 33.20 7.59 24.93 34.28 100.00

source

Variance

F ratio

A B C D error (pooled) Total

18.13 4.27 13.65 0.16 13.53

112.84 26.58 84.97 1.00

The mean for a selected trial condition for parameters at (A2, B2, C2, D3) is 0.90. The 95% confidence interval of the predicted optimum of the shock absorber defect is: 0.13< 0.90 < 1.67. Table 18 Optimum parameters under economic considerations Parameter designation A B C D Parameter Total Alkalinity (g/lit.) Temperature(oC) Rinsing water(PH) Timing(min) Optimum levels 2 2 2 3 Optimum value 70 60 7.5 10

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6. Conclusion In this study, Taguchi method has been employed for optimizing the process parameters of painting and washing during shock absorber manufacturing and the following conclusions are drawn: * It is proved that, the quality of shock absorber is improved by Taguchis method at the lowest possible cost. * Ishikawa diagram or cause and effect diagram is very effective to sort out all the possible causes affecting the shock absorber quality. * The most significant parameters affecting the quality of the shock absorber are identified by using the FMEA tool. * The parameter pointage is significantly affect the painting process and parameter timing is significantly affect the washing process. * The optimum levels of flowability, coating thickness, pointage, and temperature in painting process and total alkalinity, temperature, rinsing water, and timing in washing process are estimated. * The predicted range of optimum painting defects is 0.09<1.02< 2.13 and washing defects 0.13< 0.90 < 1.67. REFERENCES
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