Sleeve Synchronizer Induction Hardening Process Parameter Optimization For Better Hardness and Case Depth using Taguchi, Grey Relational Analysis and RABAL Algorithm – a Practical Investigation
K. Balasubramanian11, N. Rajeswari2, S. Rajarasalnath3

1K. Balasubramanian, Professor, Department of Mechanical Engineering, Bharath Institute of Higher Education and Research, Chennai (Tamil Nadu), India.
2N. Rajeswari, Professor, Department of Mechanical Engineering, St. Peter’s College of Engineering and Technology, Chennai (Tamil Nadu), India.
3S. Rajarasalnath, General Manager, NSBL Elevator Components India Pvt. Ltd., Chennai (Tamil Nadu), India.
Manuscript received on 26 March 2019 | Revised Manuscript received on 05 April 2019 | Manuscript Published on 27 April 2019 | PP: 601-607 | Volume-7 Issue-6S2 April 2019 | Retrieval Number: F90870476S219/2019©BEIESP
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Abstract: In the global competitive environment it is mandatory to operate all the manufacturing process optimally to stay competitive. Auto industries random growth, in particular, calls for lots of intricate special processes with higher quality requirement. Selection of optimization technique is also crucial, as trials are consuming cost and time and selection of process parameters, levels and experimentation methods are crucial to achieve results right first time. Sleeve synchronizer, a critical part used in manual transmissions for power shifting of first second gear. Induction hardening is one of the critical special processes involved in sleeve synchroniser manufacturing, where hardness and effective case depth are the important parameters need to be optimized simultaneously. Optimization of Sleeve synchronizer induction hardening is critical, as hardness and effective case depth cannot be checked 100% in real time environment, as effective case depth checking involves destructive testing. This research uses Taguchi parameter design coupled with grey relational analysis for simultaneous optimization of parameters for better hardness and effective case depth and it uses RABAL Algorithm to achieve results right first time. Experiments are conducted based on Taguchi L272 13 Orthogonal array, which reduces the number of trial runs from 1594323 to 27. Grey relational analysis in this research is used to convert multi objectives, hardness and effective case depth in to single grey relational grade, which is further optimized using Taguchi parameter Design. Essential care through RABAL algorithm is taken and required optimization is achieved right first time.
Keywords: Orthogonal Array, Sleeve synchronizer, Induction Hardening, Grey relational Analysis, Taguchi Parameter Design, RABAL Algorithm.
Scope of the Article: Manufacturing Processes