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Abstract
Engine Valves is one of the important parts which are used in all Internal Combustion Engines. The manufacturing process involves metal shearing, upsetting, forging, heat treatment, machining and special process. Out of these, an Upsetting process is an excellent electrically assisted preforming process for the production of high-quality engine valves. In which the copper jaws plays a vital role and are used for gripping the solid bar. In a copper jaw, there is only two sides are grooved and it will be used only for certain frequency, after exceeds that frequency it leads to run out specifications and improper formation of a bulb. So the copper jaws should replace, it will increase the cost and time to replace the jaws. In order to reduce the cost and time, four sides grooved copper jaws are used. In the upsetter machine, due to inappropriate parameters combinations could result in major defects on the valve. Based on parameter conditions, the solid bar deforms into proper bulb shape without cracks or folds. In order to reduce the defects in upsetter machine, the process parameter values are optimized using Taguchi's experimental design method and also a present effect of individual parameters on performance is estimated by using ANOVA. Confirmation tests with optimal levels of upsetting parameters are conducted to validate the test results.