Material and manufacturing technology v

Tai ngay!!! Ban co the xoa dong chu nay!!! Material and Manufacturing Technology V Edited by Meixing Guo Syed Masood Ghenadii Korotcenkov Asif Mahmood Material and Manufacturing Technology V Selected, peer reviewed papers from the 5th International Conference on Material and Manufacturing Technology (ICMMT 2014), May 8-9, 2014, Kuala Lumpur, Malaysia Edited by Meixing Guo, Syed Masood, Ghenadii Korotcenkov and Asif Mahmood Copyright  2014 Trans Tech Publications Ltd, Switzerland All rights reserved No part of the contents of this publication may be reproduced or transmitted in any form or by any means without the written permission of the publisher Trans Tech Publications Ltd Kreuzstrasse 10 CH-8635 Durnten-Zurich Switzerland http://www.ttp.net Volume 974 of Advanced Materials Research ISSN print 1022-6680 ISSN cd 1022-6680 ISSN web 1662-8985 Full text available online at http://www.scientific.net Distributed worldwide by and in the Americas by Trans Tech Publications Ltd Kreuzstrasse 10 CH-8635 Durnten-Zurich Switzerland Trans Tech Publications Inc PO Box 699, May Street Enfield, NH 03748 USA Fax: +41 (44) 922 10 33 e-mail: sales@ttp.net Phone: +1 (603) 632-7377 Fax: +1 (603) 632-5611 e-mail: sales-usa@ttp.net Preface 2014 5th International Conference on Material and Manufacturing Technology (ICMMT 2014) was held in Kuala Lumpur, Malaysia during May 8-9, 2014 The conference provides a platform to discuss Material and Manufacturing Technology etc with participants from all over the world, both from academia and from industry Its success is reflected in the papers received, with participants coming from several countries, allowing a real multinational multicultural exchange of experiences and ideas The present volumes collect accepted papers and represent an interesting output of this conference This book covers these topics: Advanced Materials Engineering and Processing Technologies, Computing and Information Technology, New Technologies, Methods and Technique in Civil Engineering, and Achievements in Medical and Engineering Sciences After the peer‐ review process, the submitted papers were selected on the basis of originality, significance, and clarity for the purpose of the conference The selected papers and additional late‐ breaking contributions to be presented as lectures will make an exciting technical program The conference program is extremely rich, featuring high‐ impact presentation We hope that the conference results constituted significant contribution to the knowledge in these up to date scientific field The proceeding records the fully refereed papers presented at the conference The main conference themes and tracks are Material and Manufacturing Technology etc Hopefully, all participants and other interested readers benefit scientifically from the proceedings and also find it stimulating in the process This conference can only succeed as a team effort, so the editors want to thank the international scientific committee and the reviewers for their excellent work in reviewing the papers as well as their invaluable input and advice Dr Meixing Guo Program Chair Guizhou University, China Committees Honorary Chairs Prof Adrian OLARU, University Politehnica of Bucharest, Romania Conference Chairs Prof Syed Masood, Swinburne University of Technology, Australia Prof Ahmed A D Sarhan, University of Malaya, Malaysia Program Chairs Dr Wasawat Nakkiew, Chiang Mai University, Thailand Dr M M Emara, Canadian International College(CIC), Egypt Dr İlhan ASİLTÜRK, Advanced Engineering and Manufacturing Laboratory (AEML), USA Dr Kyoungjin Kim, Kumoh National Institute of Technology, Korea Prof Ghenadii Korotcenkov, Gwangju Institute of Science and Technology, Korea Technical Committees Dr Pin-Chuan Chen, National Taiwan University of Science & Technology, Taiwan Dr P SIVAPRAKASH, A S L Pauls College of Engineering& Technology, India Prof Napiah Madzlan, Universiti Teknologi Petronas, Malaysia Prof Dr Mohammed Jasim Kadhim, Iraq University of Technology, Iraq Prof Guy Littlefair, Deakin University, Australia Dr S Narayanan, Senior Professor & Pro-Vice Chancellor, Vellore Institute of Technology, Vellore, India Prof L C Tsao, National Pingtung University of Science and Technology, Taiwan Prof Seyed Mehdi Rezaei, University of Malaya, Malaysia Dr Jae Hoon Lee, POSCO Technical Research Laboratories, Korea Prof Muhammad ANIS, University of Indonesia, INDONESIA Prof Dr Anika Zafiah Mohd Rus, Universiti Tun Hussein Onn Malaysia, Malaysia Prof Yu SUN, Nanjing Unviersity of Science & Technology, China Prof Taufik K Aboud, University of Tripoli, Libya Prof Lou Yan, Shenzhen University, China Dr Y S Reddy, Chaitanya Bharathi Institute of Technology, India Dr Koichiro Fukui, Yokohama National University, Japan Prof Mohsen Abdelnaeim Hassan Mohamed, University of Malaya, Malaysia Prof Anjaiah Devineni, Manipal University, India Dr Mum Wai Yip, Tunku Abdul Rahman College, Malaysia Dr Pongsaton Amornpitoksuk, Prince of Songkla University, Thailand Dr Sachin Shendokar, College of Engineering, India Dr Jiraphon Srisertpol, Suranaree University of Technology, Thailand Dr Yusairie Mohd, Universiti Teknologi Mara, Malaysia Prof Lung-Chuan Tsao, National Pingtung University of Science and Technology, Taiwan Prof Anjaiah Devineni, Manipal University, India Dr Ahmed Sarhan, University of Malaya, Malaysia Prof Ming-piao Tsai, National Formosa University, Taiwan Prof Marcus Shaffer, Department of Architecture, Pennsylvania State University, USA Prof Ho-Sung Lee, Korea Aerospace Research Institute, Korea Prof TURNAD Lenggo Ginta, UNIVERSITI TEKNOLOGI PETRONAS, MALAYSIA Prof Smit Insiripong, Muban Chombueng Rajabhat University, Thailand Dr Dhananjay M Kulkarni, Birla Institute of Technology & Science, India Prof Asif Mahmood, King Saud University (KSU), Saudi Arabia Dr TAN CHEE-FAI, Universiti Teknikal Malaysia Melaka, Malaysia Sponsors Swinburne University of Technology, Australia Table of Contents Preface, Committees and Sponsors Chapter 1: Advanced Materials Engineering and Processing Technologies Improvement of Mechanical Properties of Al2O3-SiC Composite with ZrO2 (3Y) Particles S Watcharamaisakul Prediction of Long – Term Creep Properties of Kenaf Fiber Unsaturated Polyester Composites S.A Mutasher and E.A Osman Effect of Catalyst Concentration on Performance of Hybrid CNT-Carbon Fibre Nanocomposite I.S Norazian, A.R Suraya, A Norhafizah, T.M.T Amran and N Alias Electrophoretic Deposition of Titanium Dioxide (TiO2) Nanoparticles on Ceramic Membrane M.Y Noorsuhana and N.H Abdul Aziz Green Nanoparticle Oil Well Cement from Agro Waste Rice Husk Ash N Alias, M.M.M Nawang, N.A Ghazali, T.A.T Mohd, S.F.A Manaf, A Sauki, M.Z Shahruddin and N.A Ramlee A New Double Negative Metamaterial for C-Band Microwave Applications S.I Sikder, R.I.F Mohammad and T.I Mohammad Sound Absorption Properties of Dwi Matrix Renewable and Synthetic Polymer N.Q.A Adnan and A.Z.M Rus Effect of Alkaline Phosphate-Permanganate Conversion Coating on the Corrosion Resistance of AZ91D Magnesium Alloy Y.M Byoun, J.H Jeong, J.K Park, S.K Seo and C.H Lee Formation of Cobalt Nanoparticles from Co(OH)2 Suspension M.D.L Balela, S Yagi and E Matsubara Effect of Calcination Temperature on the Morphology of Carbon Nanosphere Synthesized from Polymethylmethacrylate A.F Al-Ahmadi, M.A Al-Daous and T.A Saleh Effect of Fe Substituted Co-Free AB3-Type Hydrogen Storage Alloys Used for Ni-MH Batteries: A First-Principles Investigation M.Y Zhang, F Wu, D.B Mu and G.Q Cao Characteristics of AB3-Type Co-Free Hydrogen Storage Alloy in Low-Temperature Condition W Li, M.Y Zhang, D.B Mu, T Yang and F Wu Thermal Properties of NiCrSiB Coating on Piston Engine N.B Baba, M.M.A Omar and N.A.M Zin Material and Structural Engineering of Metal Oxides Aimed for Gas Sensor Applications G Korotcenkov and B.K Cho Investigation of Er3+ Doped in Na2O-Al2O3-BaO-CaO-Sb2O3-B2O3 -SiO2 Glasses: Physical, Optical and Visible Luminescence Properties S Tuscharoen, N Chanthima and J Kaewkhao Composite Copolymer Acrylamide/Bacterial Cellulose Hydrogel Synthesis and Characterization by the Application of Gamma Irradiation S Mulijani, Erizal, T.T Irawadi and T.C Katresna The Characterization of Chitosan-Hyaluronan-Metal Nanocomposites Y.C Shih, H.H Hsieh, T.M Wu and C.W Chou Uncured Properties of Silica Filled ENR Compounds at High Temperature Curing M.M Kamal and M.Z Zakaria Electroless Deposition of Nickel Nanoparticles at Room Temperature M.D.L Balela, S Yagi and E Matsubara 15 20 26 33 38 43 50 55 60 66 71 76 86 91 97 102 107 b Material and Manufacturing Technology V Cysteine Conjugated Gold Nanoparticles and their Scavenging Free Radicals Properties C.W Chou, J.M Yang, T.S Yang, Y.C Shih, H.H Hsieh, K.H Chang, K.S Chen, W.L Tzu, Y.C Hseu and Y.S Wei Improving the Structural, Optical and Electrical Properties of ITO Nano-Layered Thin Films by Gas Flow Argon Q.Z Mehdi, G Hegde, M.A Bin Juusoh, J.B Al-Dabbagh and N.M Ahmed Laser Assisted Machining of Ti10V2Fe3Al and Ti6Cr5Mo5V4Al β Titanium Alloys R.A Rahman Rashid, S Sun, S Palanisamy and M.S Dargusch Comparison of Endmill Tool Coating Performance during Machining of Ti6Al4V Alloy S Palanisamy, R.A Rahman Rashid, M Brandt, S Sun and M.S Dargusch Experimental Study of Micro-Milling Microchannels on Polycarbonate Substrates P.C Chen and C.W Pan Tool Life Study of Coated/Uncoated Carbide Inserts during Turning of Ti6Al4V S Palanisamy, R.A Rahman Rashid, M Brandt and M.S Dargusch Compressive Properties of Solid and Porous Parts Made from High Strength Steel Alloys by Direct Metal Deposition S.H Riza, S.H Masood and C.E Wen Computational Analysis of Single and Multiple Impacts of Low Pressure and High Pressure Cold Sprayed Aluminum Particles Using SPH S.N.A Yusof, A Manap, H Misran and S.Z Othman Characterization of Thermal Sprayed Titanium/Hydroxyapatite Composite Coating on Stainless Steel N.H Azhar, M.K Talari, R Ramli and C.K Koong Effect of Sintering Temperature on Dielectric Properties of CaCu3Ti4O12 Ceramics Prepared by Mechanochemical Process M Mohamed, M.K Talari, M.S.M Deni and A Zakaria Surface Alloying of Copper Substrate Coated by Fe-Si by Using CO2 Laser A.M.Y Taher Analysis of Roughness and Heat Affected Zone of Steel Plates Obtained by Laser Cutting I Miraoui, M Boujelbene and E Bayraktar The Influence of SS316L Foam Fabrication Parameter Using Powder Metallurgy Route N.I Mad Rosip, S Ahmad, K.R Jamaluddin and F Mat Nor Effect of Process Parameters in Hot Press Forming Operation to Tensile Strength of Ultra High Strength Steel M.Z Zawawi and N.M.H.A Nik Haron Characterization and Comparison of Thermally Sprayed Hard Coatings as Alternative to Hard Chrome Plating K Meekhanthong and S Wirojanupatump Ultimate Elastic Wall Stress (UEWS) Test under Biaxial Loading for Glass-Fibre Reinforced Epoxy (GRE) Pipes T.A Assaleh and L.A Almagguz Processability Behaviour of Dual Filler Systems Reinforced Epoxised Natural Rubber T.Z Zaeimoedin and M.M Kamal Microstructure and Hardness of Diffusion Bonded Sialon-AISI 420 Martensitic Stainless Steel N.N.M Ibrahim, P Hussain and M Awang Simulation of Dirac Tunneling Current of an Armchair Graphene Nanoribbon-Based P-N Junction Using a Transfer Matrix Method E Suhendi, R Syariati, F.A Noor, N Kurniasih and Khairurrijal Electrical Coupling of Organic/Inorganic Semiconductor Interfaces: A Comparative Study M Dhingra, S Shrivastava, P Senthil Kumar and S Annapoorni Performance Analysis of a LTE Band Microstrip Antenna on FR-4 Material A.U Ahmed, R Azim, T.I Mohammad, M Ismail and M.S Islam Measurement of Liquid Film Thickness around Horizontal Tube Bundle by Optical Technique for Optimizing Evaporator Design and Manufacturing K Bourouni and A.L Taee Study on Using EDXRF for the Determination of Gold Coating Thickness M.Y.M Sulaiman and M Muslimin 112 116 121 126 132 136 141 147 152 157 162 169 174 179 183 188 195 199 205 210 215 220 225 Advanced Materials Research Vol 974 The Effect of Oxidized White Liquor on Pulp Brightness in Peroxide Bleaching in Pulp Mills N Khajornpaisan and N Rojanarowan Tumoricidal Effect of Hematite (α-Fe2O3) and SiO2 Nanoparticles in Human Rhabdomyosarcoma Cell Line M Hammad Aziz, M Fatima, M Waseem, M Fakhar-E-Alam, M Afzal and M Nadeem Shakoor Evaluation of Mixed Cellulase-Amylase System on Enzymatic Hydrolysis Reaction Using Response Surface Methodology F Hamzah, N.H Saleh, N Alimin and M.S So’aib Influence of Shear Rate on Proteins Separation, Molecular Weight Cut-Off and Average Pore Size of Polysulfone Blend Membranes A Ali, R.M Yunus, M Awang and S Hamzah Characteristics of UV Irradiated Waste Biopolymer from Renewable Resources (Part 1) S.M Rus, N.A Latif, M.I Ghazali and A.Z.M Rus Characteristics of UV Irradiated Waste Biopolymer from Renewable Resources (Part 2) S.M Rus, M.I Ghazali and A.Z.M Rus Surface Modified Nano Calcium Oxide for Base Heterogeneous Transesterification of Kappaphycus Alvarezii Seaweed to Biofuel A.R Yacob, N.F Sulaiman and M Khalid Qasim c 230 235 241 247 252 257 262 Chapter 2: Computing and Information Technology A New Reinforcement Learning for Train Marshaling with Generalization Capability Y Hirashima Performance Enhancement of 10 Gbps OCDMA Networks Using DPSK and DQPSK with Unique Code-Sequence G.Y Li, T.T.H Gilbert and K Dimyati Vehicle Scheduling Model for Fresh Agriculture Products Pickup with Uncertain Demands L.X Rong and H.B Sha Application of Auxiliary Antenna Elements for SAR Reduction in the Human Head M.I Hossain, R.I.F Mohammad, M.T Islam and N.H.M Hanafi Thinking on the Progressive Failure Analysis of the Slope X.P Wang, X Xia, K Hu and J.C Feng The Use of the Six Sigma Approach to Minimize the Defective Rate from Bending Defects in Hard Disk Drive Media Disks S Suriyasuphapong and N Rojanarowan Extended Supply Chain DEA for Considering Replaceable DMUs W Chaowarat, H Suto and P Piboonrungroj A New Hybrid Model for Forecasting Crude Oil Price and the Techniques in the Model J.W Zheng, S.X Li and Y Kun Analysis of Elastic-Plastic Responses of a Water Tower Structure during an Earthquake Based on the Transfer Matrix Method of Multibody System H.J Huang, J.G Ding and Z Qiao 269 274 282 288 293 298 305 310 318 Chapter 3: New Technologies, Methods and Technique in Civil Engineering Nanotechnology: The Emerging Field of Civil Engineering Particularly in Developing Countries T Manzur, M Bashar Emon and K Islam An Experiment on Durability Test (RCPT) of Concrete According to ASTM Standard Method Using Low-Cost Equipments S Iffat, A.B Emon, T Manzur and S.I Ahmad Deep Pit Foundation Steel Sheet Pile Supporting Scheme of the 274# Pile Cap for Super Large Bridge over the Coastal Expressway and the North Jiangsu Irrigation Canal K Huang and R.W Feng 329 335 341 Advanced Materials Research Vol 974 411 Quality loss values and normalized quality loss values for different quality characteristics (higher-is-better) in each experimental run are calculated using equations obtained from [5] The total normalized quality loss values (TNQL) and MSNR for multiple quality characteristics for the tensile strength, hardness profile and weld quality class has been calculated using Equations mentioned in Norasiah Muhammad et all respectively [5] These results are shown in Table In calculating total normalized quality loss values, two equal weights of w1 and w2 was assigned as 0.4 for tensile strength and hardness profile , while an unequal weight of w3 with a value of 0.2 was assigned for weld quality class Higher weighting factor has been assigned to the mechanical properties rather than quality class as it is more important in order to achieve a good joint with multiple characteristics in friction stir welding process Table Multiple S/N response (average factor effect at different level) Mean of multiple S/N ratio (dB) Symbol Factors Level Level Level A Rotational Speed 1.4978 1.8688* 1.3020 B Traverse Speed 2.9312* 1.2702 0.4672 * Optimum level The effect of different control factors on MSNR is shown in Table The optimum levels of different control factors for tensile strength, hardness profile and weld quality class obtained are rotation speed at level (950rpm) and traverse speed at level (1.3mm/s) with constant axial load ANOVA technique was further employed to detect significant factors in multi-objective optimization for tensile strength, hardness profile and weld quality class The percentage contribution of different control factors on multiple quality characteristics shows that traverse speed was the major factor (71.8%), followed by rotation speed (28.2%) In Friction stir welding, traverse speed have the greatest effect on the joint quality and mechanical properties [1-4] Conclusions A multi-objective optimization has been applied with simultaneous consideration of multiple response (tensile strength, hardness profile and weld quality class) using Taguchi Method to optimize the multiple quality characteristics in FSW process Based on the optimization results, the following conclusions can be drawn: (1) The multiple characteristic such as tensile strength, hardness profile and weld quality class can be simultaneously considered using multi-objective Taguchi Method (2) The role of different control factors is traverse speed (71.8%) and rotation speed (28.2%) The traverse speed plays a major role in determining good mechanical properties and weld quality in FSW joint (3) The optimum parameters for a higher tensile strength and hardness with good weld quality is: rotation speed at level (950rpm) and traverse speed at level (1.3mm/s) 412 Material and Manufacturing Technology V Reference [1] S R Ren, Z Y Ma, and L Q Chen, “Effect of welding parameters on tensile properties and fracture behavior of friction stir welded Al–Mg–Si alloy,” Scripta Materialia, vol 56, no 1, pp 69–72, Jan 2007 [2] G B Marquis, E Mikkola, H C Yildirim, and Z Barsoum, “Fatigue Strength Improvement of Steel Structures by HFMI : Proposed Fatigue Assessment Guidelines.” [3] K Elangovan, V Balasubramanian, and S Babu, “Predicting tensile strength of friction stir welded AA6061 aluminium alloy joints by a mathematical model,” Materials & Design, vol 30, no 1, pp 188–193, Jan 2009 [4] D M Rodrigues, a Loureiro, C Leitao, R M Leal, B M Chaparro, and P Vilaỗa, Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds,” Materials & Design, vol 30, no 6, pp 1913–1921, Jun 2009 [5] N Muhammad, Y H P Manurung, R Jaafar, S K Abas, G Tham, and E Haruman, “Model development for quality features of resistance spot welding using multi-objective Taguchi method and response surface methodology,” Journal of Intelligent Manufacturing, vol 24, no 6, pp 1175–1183, May 2012 [6] G Chand and J Bunyan, “Application of Taguchi Technique for Friction Stir Welding Of Aluminum Alloy AA6061,” vol 2, no 6, pp 409–413, 2013 Advanced Materials Research Vol 974 (2014) pp 413-417 © (2014) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/AMR.974.413 Determination of Bore Grinding Machine Parameters to Reduce Cycle Time Salakjitt Buddhachakaraa and Wipawee Tharmmaphornphilasb * Industrial Engineering Department, Faculty of Engineering, Chulalongkorn University, Bangkok, Thailand a boonsalakjitt@gmail.com, b * wipawee.t@eng.chula.ac.th Keywords: Design Of Experiment, Central Composite Design, Cycle Time Reduction Abstract This paper applies a central composite design (CCD) to determine proper machine parameters to reduce the cycle time of a bore grinding process There are machine parameters, which are rough grinding starting position, fine grinding starting position, speed of rough grinding 1, speed of rough grinding 2, speed of rough grinding and speed of fine grinding and types of responses, which are cycle time and surface roughness considered in this study A half CCD is used to find the optimal machine setup parameters The experiment shows that new machine conditions can reduce cycle time from 2.98 second per piece to 2.76 second per piece and control surface roughness within specification of 1.0 um After implementing the new machine conditions in the real setting, we found that the average actual cycle time is 2.76 second per piece with roughness of 0.841 um Introduction Currently, hard disk drive (HDD) and electronic component industry in Thailand have been making significant contribution to the Thai economy A HDD requires many components such as read and write head, spindle motor, disk, suspension, and so on In this paper, we focus on an improvement of a ball bearing process A ball bearing shown in Fig.1 is used as a part in the production of a spindle motor Due to the growth in HDD industry, the demand of ball bearing is also increased Fig shows the forecast demand of ball bearing during January to December 2013 in a case study manufacturing in which the demand would go over capacity from October 2013 Therefore, the purpose of this paper is to find a way to increase productivity of a ball bearing process An experimental design method is an important tool for improving a production process In an electronic industry, an experimental design has been wildly used Asawarungsaengkul et al [1] applied a full factorial design to determine factors that significantly affect incomplete welding problem at a laser spot welding process With a new process setting, the defective rate was reduced from 0.5472% or 5,472 DPPM to 0.1775% or 1,775 DPPM Kuptasthien [2] applied a full factorial design to reduce tombstone capacitor problem at a printed circuit cable assembly process With a new process setting, the defective rate of tombstone capacitor was reduced from 1,554 DPPM to 314 DPPM Jamaluddin et al [3] applied a full factorial design to reduce the defect rate of dicing line chipping at a wafer dice process With a new machine setting, chipping size was 50% reduced Jindadee [4] applied a one half factorial design to reduce undercut defect at a laser spot welding process The result showed that defective rate of undercut defect was reduced from 0.5% to 0.32% Asawarungsaengkul [5] applied a one half factorial design to improve process yield at a gram load adjusting process of a suspension manufacturer With a new process setting, the process yield increased from 98.59% to 99.14% Krajnik [6] applied a central composite design (CCD) to find the optimal settings to minimize surface roughness The result showed that surface roughness could minimize to 0.589 um Leksakul [7] applied a central composite design (CCD) to find the optimal etching condition of a reactive ion etching (RIE) machine The results showed that wall angel and depth were closed to the target Dijoudi [8] applied a central composite design (CCD) to increase yield of a copper cementation process After implementing a new process condition, yield became 99.6% 414 Material and Manufacturing Technology V A ball bearing process is a continuous production line having automatic machines that are responsible to form ball, outer ring, and inner ring Then all parts are assembled to be a ball bearing The forecast demand shows that with a cycle time of 2.98 second per piece, a bore grinding process would not have enough capacity from October 2013 To close this gap, a target cycle time should be 2.78 second per piece A bore grinding process Bore grinding process is the process of polishing an inner diameter (ID) of an inner ring by using a grinding stone to control its diameter, shape, roughness and taper A bore grinding machine operation is controlled from a program having adjustable parameters Current conditions of the parameters and their adjustable ranges are shown in Table Parameters can be classified into groups: speed and starting position Grinding speed represents speed of the machine There are grinding types: rough grinding 1-3 and fine grinding All these speeds can be adjusted which are represented by factors C, D, E, and F in Table Grinding position represents starting position of each grinding process The machine specification allows adjusting the starting position of rough grinding and fine grinding, which are factors A and B in Table These parameters affect cycle time and also quality of the ring We want to find proper parameter settings that can reduce cycle time while control surface roughness to be within a specification Fig.1 Ball bearing Fig.2 Bore grinding capacity versus demand Table A machine condition of a bore grinding process Code of factor Description A B Rough grinding starting position Fine grinding starting position C Rough grinding speed D Rough grinding speed E Rough grinding speed F Fine grinding speed Current machine condition 0.0350 0.0100 0.0500 0.0370 0.0300 0.0040 Factor level Low (-) High (+) 0.0250 0.0050 0.0350 0.0100 0.0500 0.0550 0.0370 0.0470 0.0300 0.0400 0.0040 0.0045 Unit mm mm mm /sec mm /sec mm /sec mm /sec Advanced Materials Research Vol 974 415 Experimental Designs and Results The experimental design is employed to investigate the effect of these parameters The response variables of this experiment are cycle time of a bore grinding process and surface roughness of inner ring To screen factors, a one half-fraction 26-1 design that gives the resolution VI is applied The resolution VI of this design is enough to provide us the information about main effects and interactions [5,6] This single replicate 26-1 design and center point requires the total of 33 observations Due to the machine specification, we can get 10 samples from each observation The factors and factors level are shown in Table The analysis result show that factors A, B, C, D, E affect cycle time and factors D, E, F and EF affect surface roughness as shown in Fig and Fig Since we considers both responses together, none of them can be removed from the further experiment Normal Plot of the Standardized Effects Normal Plot of the Standardized Effects (response is Cycle Time, Alpha = 0.05) (response is Roughness, Alpha = 0.05) 99 Effect Ty pe Not Significant Significant B F actor A B C D E F Percent 80 70 60 50 40 30 N ame A B C D E F Effect Type Not Significant Significant F 95 E 90 F actor A B C D E F D EF 80 70 Percent A 95 90 99 60 50 40 30 20 Name A B C D E F 20 E 10 10 D 5 C 1 -5 10 Standardized Effect 15 20 10 15 20 Standardized Effect 25 30 Fig Normal plot of the standardized effectsfor Fig Normal plot of the standardized effects for cycle time roughness To find the optimal levels of the parameters, central composite design (CCD) is used This central composite half design requires 53 observations We take 33 observations from the previous 26-1 design so 20 additional observations are performed All 53 observations are collected according to the experimental plan Before performing further statistical analysis, all assumptions are verified The residual plots are shown in Fig and Fig The residuals of cycle time and roughness are normally distributed Plots of residuals versus Fits not show any trend or cyclical patterns so variances are stable Plots of residuals versus run order not show any trend or cyclical patterns so the independence assumption is satisfied Residual Plots for Cycle Time Residual Plots for Roughness Normal Probability Plot Normal Probability Plot Versus Fits 99 Versus Fits 99 0.030 0.050 10 90 0.025 0.000 -0.025 0.000 0.025 Residual 0.050 2.7 2.8 Histogram -0.04 3.0 5.0 2.5 0.025 0.000 -0.025 -0.050 0.0 -0.06 -0.03 0.00 Residual 0.03 0.06 10 15 20 25 30 35 40 45 50 Observation Order Fig Residual plots for cycle time 0.00 Residual 0.02 0.04 0.8 Histogram Frequency Residual 7.5 0.000 -0.030 -0.02 Versus Order 0.050 10.0 Frequency 2.9 Fitted Value 0.015 -0.015 0.9 Fitted Value 1.0 Versus Order 16 0.030 12 0.015 Residual -0.025 50 10 -0.050 -0.050 Residual 50 Percent Residual Percent 90 0.000 -0.015 -0.030 -0.024 -0.012 0.000 0.012 Residual 0.024 10 15 20 25 30 35 40 45 50 Observation Order Fig Residual plots for roughness We also perform a stepwise regression to find a relation between factor and response to predict cycle time and roughness as in equations (1) and (2) 416 Material and Manufacturing Technology V Cycle Time = 2.974 + 15.7 Rough grinding starting position +12.4 Fine grinding starting position -7.8 Rough grinding speed -3.6 Rough grinding speed -2.9 Rough grinding speed (1) Roughness = 0.3023 + 7551 Rough grinding speed*Fine grinding speed -21.3 Rough grinding speed + 5.20 Rough grinding speed (2) The analysis of response surface design on the cycle time and roughness are performed CCD is used to find the optimal parameter settings In this case we want the settings where cycle time is minimized while surface roughness is within specification Therefore, roughness is set at 0.85 um., which equals to the performance level before adjusting machine, to search for the minimum cycle time Table and Fig show the optimal process parameters With these settings the new cycle time is 2.76 second per piece or 7.38% reduction Table New machine setting condition of bore grinding process New machine condition Code of factor Description 0.0250 A Rough grinding starting position 0.0050 B Fine grinding starting position 0.0550 C Rough grinding speed 0.0370 D Rough grinding speed 0.0040 E Rough grinding speed 0.0040 F Fine grinding speed Optimal High D Cur 1.0000 Low A 0.0350 [0.0250] 0.0250 B 0.010 [0.0050] 0.0050 C 0.0550 [0.0550] 0.050 D 0.0470 [0.0370] 0.0370 E 0.040 [0.040] 0.030 Unit mm mm mm /sec mm /sec mm /sec mm /sec F 0.0045 [0.0040] 0.0040 Composite Desirability 1.0000 Cycle Ti Minimum y = 2.7556 d = 1.0000 Roughnes Targ: 0.850 y = 0.8500 d = 1.0000 Fig The optimal process parameters We implemented the optimal parameter levels in the real setting to produce 150,000 pieces of inner ring The actual average cycle time is 2.76 second per piece with average roughness surface of 0.841 um., which close to the result from the experiment of the central composite design Advanced Materials Research Vol 974 417 Conclusion This paper aims to reduce cycle time of a bore grinding process while controlling surface roughness of an inner ring’s inner diameter The experimental design is employed to determine proper machine settings There are parameters that can be experimented At the beginning, the 26-1 design is conducted to screen factors However, none of the factors can be removed from the experiment CCD is performed to find the optimal factor levels by setting surface roughness within a specification to obtain the minimum cycle time The confirmation experiment reveals that cycle time after adjusting machine is reduced from 2.98 second per piece to 2.76 second per piece and surface roughness of inner diameter is 0.841 um which meets the requirement References [1] K Asawarungsaengkul, J Deeying and P Boonpalit: Quality Improvement on the Laser Spot Welding Process of a Suspension Manufacturer (The 5th PSU-UNS International Conference on Engineering and Technology (ICET-2011), 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