FINAL YEAR PROJECT 2

DATA ANALYSIS: EXPERIMENT

NORLIANA MOHD ABBAS, PhD

20 MARCH 2018

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 PROFILE
NORLIANA MOHD ABBAS
Doctor of Philosophy in Precision Engineering, The University of Tokyo
Master of Science in Mechanical Engineering, Universiti Teknologi MARA
Bachelor of Engineering with Honours (Mechanical), Universiti Teknologi MARA
Diploma in Mechanical Engineering, Universiti Teknologi Malaysia

Area of expertise: Electrical Discharge Machining (EDM)

PhD Supervisor: MSc Supervisor:

Prof. Dr. Masanori Kunieda Prof. Dr. Darius G. Solomon
(photo taken in 2015) (photo taken in 2016)
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 OVERVIEW

1. Introduction
Presentation of research methodology

1. Data collection and presentation

2. Analysis of data
a) Table
b) Graph
c) Image

4. Conclusion
3
 INTRODUCTION
What is the purpose of Undergraduate Final Year
Project?
Basically, to expose student to solve problem systematically

Steps involved
1. Define problem
2. Investigate possible solutions
3. Methodology
4. Conduct experiment / observation
5. Data collection
6. Analysis of data
7. Conclude findings
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 IMPORTANT!!
PROJECT METHODOLOGY

Good and reliable data can be obtained from the

BEST METHODOLOGY As the technology evolve, better
tools/machine/equipment is
1.Method should be clearly explain available; making the difficult
2.Device should be clearly shown method, possible

What does CLEAR means?

Readers should be able to:

1. Understand
2. Replicate your steps and obtain nearly similar result

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 BASIC WRITING RULES

1. Which one is correct?

Fig. 1. Experimental setup
Fig. 1: Experimental setup
Figure 1: Experimental setup

2. Write the information, FIRST…. followed by the figure / table

3. The figure title is often written 4. The table title is often written
BELOW the figure ABOVE the figure

Table 1: Class attendance

Name Student ID

Fig. 1: Surface grinding process 6

 IMPORTANT!!
HOW METHODOLOGY SHOULD BE PRESENTED
Example 1:

Fig. 1 shows the equipment used to drill micro holes with

electrical discharge machining.

Fig. 1: Equipment

Does this figure gives any useful information???

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 IMPORTANT!!
HOW METHODOLOGY SHOULD BE PRESENTED

Example 2:

Fig. 2 shows the equipment used in

the experiment to drill micro holes
with electrical discharge machining.
The tool electrode is fixed at the
end of the tool electrode holder,
which is supported by the V-shape
ceramic guides. The holder is Fig. 2: Experimental setup
rotated by a rubber belt hooked on
the pulley. The V-shape ceramic
guides enable precise rotation of
the tool electrode [8]. Now, can you see
the difference??? 8
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 IMPORTANT!!
HOW METHODOLOGY SHOULD BE PRESENTED

If photo is used, additional information may be needed to

assist the understanding of the readers
Mandrel Feeding
electrode

4 pairs
Feeding L = 11.4mm
electrode

7 pairs
Mandrel L = 19.8mm Outer
Inner
Gap: 0.1mm

Fig. 3: Assembly of 7 pairs labyrinth Fig. 4: Crossectional view of

feeding electrode on micro EDM machine labyrinth feeding electrode
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 DATA COLLECTION AND
PRESENTATION
1. Should answer the question/s of your investigation

2. Must tell readers what are the key results

3. Interpretation of results includes

a) How your results modify and fit in and how/what was
previously understood about the problem

b) Review of literature: some literature may be overlooked

or may relate to your own interpretation

Key points:
1. LOGIC
2. SUFFICIENTLY MINIMUM
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 DATA PRESENTATION

a) Table b) Graph

Presented data should give

information to the readers!!

What do you
c) Figure / Image want to show???
Fig. 5: Types of data presentation
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 Analysis of Data: A) Table (1)
Table is a simple way to show results

What is important?
1. Table number & title
2. Column and row

In my area, table is not popular and usually used to show the result
of statistical calculation
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 Analysis of Data: A) Table (1)

The ANOVA for the MRR is summarized in Table 3. The F-value, P-value, R2
and adjusted R2 are employed for identifying the more significant model and
coefficients. Larger F-value, R2 and adjusted R2 , and smaller P-value show
that the model or a coefficient is significant. According to Table 3, the F-value,
P-value, R2 and adjusted R2 for the predicted MRR is 112.43, <0.0001,
0.9751, 0.9664. Thus, it can be concluded that the models predict adequately.

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 Analysis of Data: B) Graph (1)

Example of graph and its important information

Results may be differentiate
using different color or pattern
Axis:
i) Scale Legend
(in my opinion, this
ii) Unit method is best)
iii) Abbreviation (if needed)

i) Fig. number
(depends on format)
ii) Title of figure Fig. 6: Influence of resistance of electrode, Re
iii) Standardization
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 Analysis of Data: B) Graph (2)

Example of a graph presentation and its important information

Results with error-bar Parameter may be added

for easy understanding

Results may be
differentiate
using different
marker
Legend
(in my opinion, this
method is best)

Fig. 7: Influence of resistivity of workpiece on discharge current

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 Analysis of Data: B) Graph (3)

Another sample on graph presentation

Year 2016 2017 2018

100

80 74.2 77.7
69.2
62.6 62.7
Score

60 56.2 56.6 59.9 57.7

49.6 51.0 52.7

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20

0
Academic Employer Citation H-Index
Reputation Reputation

Fig. 8: Overall score for three years research performances

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 Analysis of Data: B) Graph (4)

What is wrong with this graph?

10

Resonant frequency , fr
10

Resonant frequency (MHz)

9 9
8 8 Experiment

(MHz)
7 7
6 Calculation
6
5 5
4
4
3
3 100 200 300 400 500
100 200 300 400 500
Capacitance, C1 (pF)
Capacitance, C1 (pF)
Fig. 9: Relationship between resonant frequency, fr
and capacitance, C1

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 Analysis of Data: B) Graph (5)

What is wrong with this graph?

side-by-side comparison

Resonant frequency (MHz), fr

10 10
Resonant frequency (MHz)

9 9
8 8
Experiment
7 7
6 Calculation
6
5 5
4 4
3 3
100 200 300 400 500 100 200 300 400 500
Capacitance, C1 (pF) Capacitance, C1 (pF)

Fig. 9: Relationship between resonant

frequency, fr and capacitance,18 C1
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 Analysis of Data: B) Graph (6)

Example of graph explanation

Comment:
Explanation can be as simple
as this.

You do not have to compare

every line in the graph.

Readers can clearly see this!!

Fig. 6: Influence of resistance of electrode, Re.

Fig. 6 shows the calculated discharge current waveforms. When the

electrode resistance Re increases, the peak value of the discharge current
decreases, whereas the pulse duration (time) increases.

I added this because, you may not understand 19

 Analysis of Data: B) Graph (7)
Example of graph explanation

Fig. 10: Relationship between TWR and feed speed

Fig. 10 shows the results on tool wear ratio (TWR). TWR was obtained by dividing
the volume of tool wear with the removal volume of workpiece. Under the same
feed speed, TWR was lower with the controlled pulse train method (CPTM). In
conventional EIFM, the discharge with a high peak current within short duration
in alternating polarity caused high tool wear [4]. With CPTM however, bipolar
high frequency discharge over a long period of time in oil dielectric leads to
carbon deposition on the tool surface, preventing excessive wear. It is well known
that longer discharge duration results in lower TWR because of the carbon
deposition [5-7]. 20
 Analysis of Data: B) Graph (8)
Example of graph explanation: line by line
1. Which figure? What does it shows?
Fig. 10 shows the results of the tool wear
ratio (TWR).
Comment:
This does not have to be the same as the title of
the figure

2. How TWR was obtained?

Fig. 10: Relationship between
TWR and feed speed
* In machining, low tool wear
(TWR) is a desirable condition
TWR was obtained by dividing the volume
of tool wear with the removal volume of
workpiece.
3. What is obvious?
Under the same feed speed, TWR was
lower with the controlled pulse train method
(CPTM).

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 Analysis of Data: B) Graph (9)
Example of graph explanation: line by line

4. What is “normal” or previously found?

In conventional EIFM, the discharge with a
high peak current within short duration in
alternating polarity caused high tool wear [4].

Comment:
Conventional EIFM method is relatively new,
Fig. 10: Relationship between TWR thus reference is added.
and feed speed

5. What is current result. Why there is difference between the 2 lines?

With CPTM however, bipolar high frequency discharge over a long period of
time in oil dielectric leads to carbon deposition on the tool surface, preventing
excessive wear. It is well known that longer discharge duration results in
lower TWR because of the carbon deposition [5-7].
Comment: 22
Based on physics or theory, explanation is given. Reference can be added. This is
important!!! 22
 Analysis of Data: B) Graph (10)

Example of graph presentation

Fig. 11: Progress of method in combining ultrasonic Fig. 12: Research studies
vibration with EDM from year 1995-2006 conducted in dry23 EDM
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 Analysis of Data: C) Figure/Image (1)

Important information

1. Figure number
2. Clear image
3. Obvious similarity or differences
4. Scale on figure
5. Additional graph may be needed to further
explain the image

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 Analysis of Data: c) Figure/Image (2)

Example 1: waveforms (observation)

Fig. 13:

1. Figure number
2. Scale: comparison must be at the same scale!!
3. Label
4. Similarity or differences

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 Analysis of Data: c) Figure/Image (3)

Example 1: waveforms (observation)

Fig. 13:

Fig. 13 shows the comparison between the incomplete and complete discharge
currents within the same pulse train duration for 3MHz. Duration of single pulse
discharge is the same. In the present work, the discharge duration was 50ns at C1 =
470pF. Hence, low frequency of 3MHz results in longer interval between
individual pulse discharges, leading to deionization of the plasma. This is the
reason why the discharges are interrupted within the pulse train duration.

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 Analysis of Data: c) Figure/Image (4)
Top/side image
Example 2: Image should be used What can you “get” from this
figure??

The AISI D6 tool steels with 20 mm

Scale shown
below the figure
Microscope observation
of machined surface You cannot see clearly the difference
Fig. 14: (a) The workpieces before
EDM, (b) copper electrodes
and (c) final productions.
diameter and 20 mm thick were used
as workpieces. Also, circular
electrolytic copper with 18 mm
diameter were utilized as electrodes.
The workpieces before EDM,
electrodes and final productions in
this study are illustrated in Fig. 14.
between them.
How can you improve the quality of
the figure? Or how to make it easy to
understand? 27
 Analysis of Data: c) Figure/Image (5)

Example 3: scanning electron microscope (SEM)

You may add
Identification/information on the figure shown
the ring to
highlight the
diameter of the
crater

Visibility of
the image
shown

Scale
Fig. 15: Discharge craters generated on the stainless steel workpiece

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 Analysis of Data: c) Figure/Image (6)
Example of figure and explanation

Fig. 16 shows the discharge craters

generated on the stain-less steel
workpiece using the tungsten and
silicon tool electrode. The diameter of
discharge craters generated using the
silicon tool electrode was smaller than
that when using the tungsten tool
electrode.

Comment:
How do you know?
It looks the same!!!
Extra information need to be shown
Fig. 16: Discharge craters generated on the
stainless steel workpiece. 29
 Analysis of Data: c) Figure/Image (7)

Example of figure and explanation

Thus, the authors measure

the diameter of discharge
crater obtained from the
image and tabulate in a graph

Fig. 17: Diameter of discharge craters on

the stainless steel workpiece.

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 Analysis of Data: c) Figure/Image (8)
Example of figure and explanation
What can be seen?
Fig. 17 shows the relationship between the
diameters of discharge craters and tool
electrode resistivity.

The average diameter of discharge craters

generated by the tungsten tool electrode is
approximately 1.2µm, whereas those by silicon
electrodes are distributed in the range
approximately 0.5–0.8µm.

With increasing silicon electrode resistivity, the

diameter of discharge craters decreased.
Fig. 17: Diameter of discharge Why???
craters on the stainless
This is because the discharge current
steel workpiece.
flowing from the stray capacitance was
limited by the resistance of the silicon tool
electrode. 31
 Analysis of Data: c) Figure/Image (9)

By measuring the diameter of discharge craters and represent

it in graph, the information is more significant

Fig. 16: Discharge craters generated on Fig. 17: Diameter of discharge craters on
the stainless steel workpiece. the stainless steel workpiece. 32
 Analysis of Data: c) Figure/Image (10)

Finite Element Method/Analysis

Fig. 18: The physical body (continuum) is modeled by dividing it into

an equivalent assembly of smaller bodies or units
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From presentation slides prepared by Dr Abdul Halim Abdullah, FKM Shah Alam
 Analysis of Data: c) Figure/Image (11)

Finite Element Method/Analysis General Steps:

Pre-processing
1 - Geometry
2 - Elements
3 - Materials
4 - Meshing
5 - Assembly
6 - Boundary Condition
Solution
7 - Solution
Post-processing
8 - Results
60kg

Model Material E (GPa) v

1 Acetabular cup Ti6Al4V 114 0.34 5 1
2 Polyethylene liner UHMWPE 1.95 0.43 2
3 Femoral ball Alumina 370 0.23 3
4 Prosthesis stem Ti6Al4V 114 0.34 4
5 Hip cartilage cartilage 0.004 0.4
7
6 Right Femur (non-operated) Inhomogeneous model 34
6
7 Left femur (operated THA) Inhomogeneous model fixed

From presentation slides prepared by Dr Abdul Halim Abdullah, FKM Shah Alam
 Analysis of Data: c) Figure/Image (12)
Finite Element Method/Analysis

Fig. 19: 2-D modeling and simulation of Fig. 20: 3-D static stress analysis
a urethane piston seal on a piston

35

From presentation slides prepared by Dr Abdul Halim Abdullah, FKM Shah Alam
 Analysis of Data: c) Figure/Image (13)

Finite Element Method/Analysis

Focus area / stress concentration

THA
proximal 11.93 hip OA
region 27.33

distal 32.53 MPa

region 23.39

0.0 10.0 20.0 30.0 40.0

max. principal stress (MPa)

Percentage of differences;
Proximal region = -56.36 %
(bone resorption)
Distal region = 39.08 %
(bone thickening) 36

before after
From presentation slides prepared by Dr Abdul Halim Abdullah, FKM Shah Alam
 Analysis of Data: c) Figure/Image (14)

Finite Element Method/Analysis

• The contour colour results  not enough

• Keep asking yourselves : So, what, why?

• Common questions….
i. Why there is a scale colour? What does it
Fig. 21: Loading and boundary conditions represent?
applied in the femur and THR femur ii. Why von-mises stress?
iii. Why maximum principal stress?
iv. Total deformation? What does it
represent?
v. How the results match to your objectives?

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Fig. 22: Stress distribution in THR femur

From presentation slides prepared by Dr Abdul Halim Abdullah, FKM Shah Alam
 Analysis of Data: c) Figure/Image (14)
Finite Element Method/Analysis
Things to be discussed
1. Validation of your findings
2. Compare your work with other researcher
3. Room for improvement

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Fig. 23: Comparison between experiment and simulation
From presentation slides prepared by Dr Abdul Halim Abdullah, FKM Shah Alam
 CONCLUSIONS

1. Good report writing allows readers to understand and able

to replicate the experiment.

2. The purpose of showing table, graph or figure are to give

information to readers. Thus, good presentation and
elaboration is needed.

3. Questions which may help you to elaborate your

explanation:
a) What does the figure shows?
b) How it was obtained?
c) Why it happened?

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THANK YOU

T1-A11-6C
Faculty of Mechanical Engineering
Universiti Teknologi MARA (UiTM)
40450 Shah Alam, Selangor
MALAYSIA

Email: norliana@salam.uitm.edu.my
norlianabbas1980@gmail.com
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