Ms. Jaya Valyan

Dr. Suraj Rane

Abstract

Design of Experiments (DOE) is a systematic and well-defined optimization techniques used in wide applications in industries and academic research. In this paper, a cylindrical component broached on a FIMAT machine with 14 fixtures is studied to optimize the CTQ; wall thickness. The wall thickness is defined as the step diameter minus the broaching depth. The objective is to optimize the parameter setting so that wall thickness meets part specification i.e. 1.15 to 1.35 mm. The process capability of the current process was found to be 0.68, which is very low on quality requirement resulting in 4.6 % defectives. It was decided to use Design of experiments approach to find optimal level of input parameters. Following factors were considered for conducting DOE; outer diameter, step diameter, type of fixture and broach blade height setting. The main effects and interaction effects were studied for their contribution to ANOVA. The outcome of the study was improvement in process capability and reduction in defective percentage.

Keywords- DOE, broaching, process capability, quality improvement, ANOVA