Mechanical Engineering Department

MET 902: Design of Experiments and Optimization

Tutorial 5: Fractional Factorial Designs

1. A nickel-titanium alloy is used to make components for jet turbine aircraft engines. Cracking is a
potentially serious problem in the final part, because it can lead to non-recoverable failure. A
test is run at the parts producer to determine the effect of four factors on cracks. The four
factors are pouring temperature (A); titanium content (B); heat treatment method (C); and
amount of grain refiner used (D). Two replicates of a 24 design are run, and the length of crack
(in mm x10−2 ) induced in a sample coupon subjected to a standard test is measured. The data
are shown in the following table:

A B C D Treatment Replicate

Combination I II

- - - - (1) 7.037 6.376

+ - - - a 14.707 15.219

- + - - b 11.635 12.089

+ + - - ab 17.273 17.815

- - + - c 10.403 10.151

+ - + - ac 4.368 4.098

- + + - bc 9.360 9.253

+ + + - abc 13.440 12.923

- - - + d 8.561 8.951

+ - - + ad 16.867 17.052

- + - + bd 13.876 13.658

+ + - + abd 19.824 19.639

- - + + cd 11.846 12.337

+ - + + acd 6.125 5.904

- + + + bcd 11.190 10.935

 + + + + abcd 15.653 15.053

(a) Estimate the factor effects

(b) Conduct ANOVA at significance level 0.05
(c) Perform error analysis
(d) What recommendations do you make regarding process operations?
(e) Suppose only a one-half fraction of the 24 design could be run. Construct the design and
perform the analysis, using the data from replicate I.

2. In article by J. J. Pignatiello, Jr. and J. S. Ramberg in the Journal of Quality Technology (Vol. 17,
1985, pp. 198-206) describes the use of a replicated fractional factorial to investigate the effect
of five factors on the free height of leaf springs used in an automotive application. The factors
are A = furnace temperature, B = heating time, C = transfer time, D = hold down time, and E =
quench oil temperature. The data are shown below:

A B C D E Free Height

- - - - - 7.78 7.78 7.81

+ - - + - 8.15 8.18 7.88

- + - + - 7.50 7.56 7.50

+ + - - - 7.59 7.56 7.75

- - + + - 7.54 8.00 7.88

+ - + - - 7.69 8.09 8.06

- + + - - 7.56 7.52 7.44

+ + + + - 7.56 7.81 7.69

- - - - + 7.50 7.25 7.12

+ - - + + 7.88 7.88 7.44

- + - + + 7.50 7.56 7.50

+ + - - + 7.63 7.75 7.56

- - + + + 7.32 7.44 7.44

 + - + - + 7.56 7.69 7.62

- + + - + 7.18 7.18 7.25

+ + + + + 7.81 7.50 7.59

(a) Write out the alias structure for this design. What is the resolution of this design?
(b) Analyze the data. What factors influence the mean free height?
(c) Analyze the residuals from this experiment, and comment on your findings.
(e) Is this the best possible design for five factors in 16 runs? Specifically, can you find a
fractional design for five factors in 16 runs with a higher resolution than this one?

3. Heat treating is often used to carbonize metal parts, such as gears. The thickness of the
carbonized layer is a critical output variable from this process, and it is usually measured by
performing a carbon analysis on the gear pitch (the top of the gear tooth). Six factors were
studied in a design: A = furnace temperature, B = cycle time, C = carbon concentration, D =
duration of the carbonizing cycle, E = carbon concentration of the diffuse cycle, and F = duration
of the diffuse cycle. The experiment is shown below:

Standar Run A B C D E F Pitch

d
Order
Order

1 5 - - - - - - 74

2 7 + - - - + - 190

3 8 - + - - + + 133

4 2 + + - - - + 127

5 10 - - + - + + 115

6 12 + - + - - + 101

7 16 - + + - - - 54

8 1 + + + - + - 144

9 6 - - - + - + 121

10 9 + - - + + + 188

11 14 - + - + + - 135
 12 13 + + - + - - 170

13 11 - - + + + - 126

14 3 + - + + - - 175

15 15 - + + + - + 126

16 4 + + + + + + 193

(a) Estimate the factor effects and plot on a normal probability plot. Select a tentative model.
(b) Perform appropriate statistical tests on the model.
(c) Analyze the residuals and comment on model adequacy.
(d) Interpret the results of this experiment. Assume that a layer thickness of between 140 and
160 is desirable.