Search results for: taguchi analysis

Authors: Karima Megdouli

Abstract:

The ejector, a central element within the CO₂ transcritical ejection refrigeration system, holds significant importance in enhancing refrigeration capacity and minimizing compressor power usage. This study's objective is to introduce a technique for enhancing the effectiveness of the CO₂ transcritical two-phase ejector, utilizing Taguchi and ANOVA analysis. The investigation delves into the impact of geometric parameters, secondary flow temperature, and primary flow pressure on the efficiency of the ejector. Results indicate that employing a combination of Taguchi and ANOVA offers increased reliability and superior performance when optimizing the design of the CO₂ two-phase ejector.

Keywords: ejector, supersonic, Taguchi, ANOVA, optimization

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Authors: Vinay Patil, Swapnil Kekade, Ashish Supare, Vinayak Pawar, Shital Jadhav, Rajkumar Singh

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In recent days, bainitic steel is used in automobile and non-automobile sectors due to its high strength. Bainitic steel is difficult to machine because of its high hardness, hence in this paper machinability of bainitic steel is studied by using Taguchi design of experiments (DOE) approach. Convectional turning experiments were done by using L16 orthogonal array for three input parameters viz. cutting speed, depth of cut and feed. The Taguchi method is applied to study the performance characteristics of machining parameters with surface roughness (Ra), cutting force and tool wear rate. By using Taguchi analysis, optimized process parameters for best surface finish and minimum cutting forces were analyzed.

Keywords: conventional turning, Taguchi method, S/N ratio, bainitic steel machining

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Authors: Varsha Singh, Kishan Fuse

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This paper presents a study of the grey-Taguchi method to optimize CNC milling parameters of AA6061 T6 aluminium alloy. Grey-Taguchi method combines Taguchi method based design of experiments (DOE) with grey relational analysis (GRA). Multi-response optimization of different quality characteristics as surface roughness, material removal rate, cutting forces is done using grey relational analysis (GRA). The milling parameters considered for experiments include cutting speed, feed per tooth, and depth of cut. Each parameter with three levels is selected. A grey relational grade is used to estimate overall quality characteristics performance. The Taguchi’s L9 orthogonal array is used for design of experiments. MINITAB 17 software is used for optimization. Analysis of variance (ANOVA) is used to identify most influencing parameter. The experimental results show that grey relational analysis is effective method for optimizing multi-response characteristics. Optimum results are finally validated by performing confirmation test.

Keywords: ANOVA, CNC milling, grey relational analysis, multi-response optimization

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Authors: Harish Kumar Ponnappan, Joseph C. Chen

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The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L₉ orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.

Keywords: live tooling, surface roughness, taguchi analysis, CNC milling operation, CNC turning operation

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Authors: Nurul Na'imy Wan, Mohamad Sazali Said, Jaharah Ab. Ghani, Mohd Asri Selamat

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This paper presents the surface roughness of the Aluminium silicon alloy (AlSi) matrix composite which has been reinforced with aluminium nitride (AlN), with three types of carbide inserts. Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to the Taguchi method, using a standard orthogonal array L27 (34). The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of machining parameters in measuring the surface roughness during the milling operation. The analysis of results, using the Taguchi method concluded that a combination of low feed rate, medium depth of cut, low cutting speed, and insert TiB2 give a better value of surface roughness. From Taguchi method, it was found that cutting speed of 230m/min, feed rate of 0.4 mm/tooth, depth of cut of 0.5mm and type of insert of TiB2 were the optimal machining parameters that gave the optimal value of surface roughness.

Keywords: AlSi/AlN Metal Matrix Composite (MMC), surface roughness, Taguchi method

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Authors: Amara Prakasa Rao, N. V. S. N. Sarma

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This paper describes the synthesis of linear array geometry with minimum sidelobe level and null control using the Taguchi method. Based on the concept of the orthogonal array, Taguchi method effectively reduces the number of tests required in an optimization process. Taguchi method has been successfully applied in many fields such as mechanical, chemical engineering, power electronics, etc. Compared to other evolutionary methods such as genetic algorithms, simulated annealing and particle swarm optimization, the Taguchi method is much easier to understand and implement. It requires less computational/iteration processing to optimize the problem. Different cases are considered to illustrate the performance of this technique. Simulation results show that this method outperforms the other evolution algorithms (like GA, PSO) for smart antenna systems design.

Keywords: array factor, beamforming, null placement, optimization method, orthogonal array, Taguchi method, smart antenna system

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Authors: Thirasak Panyaphirawat, Pairoj Sapsmarnwong, Teeratas Pornyungyuen

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This paper presents the findings of an experimental investigation of important machining parameters for the horizontal boring tool modified to mouth with a horizontal lathe machine to bore an overlength workpiece. In order to verify a usability of a modified tool, design of experiment based on Taguchi method is performed. The parameters investigated are spindle speed, feed rate, depth of cut and length of workpiece. Taguchi L9 orthogonal array is selected for four factors three level parameters in order to minimize surface roughness (Ra and Rz) of S45C steel tubes. Signal to noise ratio analysis and analysis of variance (ANOVA) is performed to study an effect of said parameters and to optimize the machine setting for best surface finish. The controlled factors with most effect are depth of cut, spindle speed, length of workpiece, and feed rate in order. The confirmation test is performed to test the optimal setting obtained from Taguchi method and the result is satisfactory.

Keywords: design of experiment, Taguchi design, optimization, analysis of variance, machining parameters, horizontal boring tool

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Authors: Nurul Na'imy Wan, Mohamad Sazali Said, Jaharah Ab. Ghani, Rusli Othman

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This paper presents the surface roughness of the aluminium silicon alloy (AlSi) matrix composite which has been reinforced with aluminium nitride (AlN). Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to a standard orthogonal array L27 of Taguchi method using TiN coating tool of insert. The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of cutting speeds, feed rates and depths of cut in measuring the surface roughness during the milling operation. The surface roughness was observed using Mitutoyo Formtracer CS-500 and analyzed using the Taguchi method. From the Taguchi analysis, it was found that cutting speed of 230 m/min, feed rate of 0.4 mm/tooth, depth of cut of 0.3 mm were the optimum machining parameters using TiN coating insert.

Keywords: AlSi/AlN metal matrix composite (MMC), surface roughness, Taguchi method, machining parameters

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Authors: Jumazulhisham Abdul Shukor, Mohd. Sazali Said, Roshanizah Harun, Shuib Husin, Ahmad Razlee Ab Kadir

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This paper applies Taguchi Optimization Method in determining the best machining parameters for pocket milling process on Polypropylene (PP) using CNC milling machine where the surface roughness is considered and the Carbide inserts cutting tool are used. Three machining parameters; speed, feed rate and depth of cut are investigated along three levels; low, medium and high of each parameter (Taguchi Orthogonal Arrays). The setting of machining parameters were determined by using Taguchi Method and the Signal-to-Noise (S/N) ratio are assessed to define the optimal levels and to predict the effect of surface roughness with assigned parameters based on L9. The final experimental outcomes are presented to prove the optimization parameters recommended by manufacturer are accurate.

Keywords: inserts, milling process, signal-to-noise (S/N) ratio, surface roughness, Taguchi Optimization Method

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Authors: Enes Furkan Erkan, Özer Uygun, Halil Ibrahim Demir, Zeynep Demir

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Companies require increase in quality perception level of their products due to competitive conditions. As a result, the tendency to quality and researches to develop the quality are increasing day by day. Cost and time constraints are the biggest problems that companies face in their quality improvement efforts. In this study, factors that affect the porosity of ceramic products are determined and analyzed in a factory producing ceramic tiles. Then, Taguchi method is used in the design phase in order to decrease the number of tests to be performed by means of orthogonal sequences. The most important factors affecting the porosity of ceramic tiles are determined using Taguchi and ANOVA analysis. Based on the analyses, the most affecting factors are determined to be used in the fuzzy implementation stage. Then, the fuzzy rules were established with the factors affecting porosity by the experts’ opinion. Thus, porosity result could be obtained not only for the specified factor levels but also for intermediate values. In this way, it has been provided convenience to the factory in terms of cost and quality improvement.

Keywords: fuzzy, porosity, Taguchi Method, Taguchi-Fuzzy

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Authors: Karima Megdouli, Bourhan tachtouch

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Ejector refrigeration cycles offer an alternative to conventional systems for producing cold from low-temperature heat. In this article, a thermodynamic model is presented. This model has the advantage of simplifying the calculation algorithm and describes the complex double-throttling mechanism that occurs in the ejector. The model assumption and calculation algorithm are presented first. The impact of each efficiency is evaluated. Validation is performed on several data sets. The ejector model is then used to simulate a RES (refrigeration ejector system), to validate its robustness and suitability for use in predicting thermodynamic cycle performance. A Taguchi and ANOVA optimization is carried out on a RES. TOPSIS analysis was applied to decide the optimum refrigerants with cost, safety, environmental and enviro economic concerns along with thermophysical properties.

Keywords: ejector, velocity distribution, shock circle, Taguchi and ANOVA optimization, TOPSIS analysis

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Authors: Othman Mohamed Altheni, Abdurrahman Abusaada

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This study presents optimization of multiple performance characteristics [material removal rate (MRR), surface roughness (Ra), and overcut (OC)] of hardened AISI D3 tool steel in electrical discharge machining (EDM) using Taguchi method and Grey relational analysis. Machining process parameters selected were pulsed current Ip, pulse-on time Ton, pulse-off time Toff and gap voltage Vg. Based on ANOVA, pulse current is found to be the most significant factor affecting EDM process. Optimized process parameters are simultaneously leading to a higher MRR, lower Ra, and lower OC are then verified through a confirmation experiment. Validation experiment shows an improved MRR, Ra and OC when Taguchi method and grey relational analysis were used

Keywords: edm parameters, grey relational analysis, Taguchi method, ANOVA

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Authors: Mohamed Zakaulla, A. R. Anwar Khan

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Al6061 alloy base matrix, reinforced with particles of silicon carbide (10 wt %) and Graphite powder (1wt%), known as hybrid composites have been fabricated by liquid metallurgy route (stir casting technique) and optimized at different parameters like applied load, sliding speed and sliding distance by taguchi method. A plan of experiment generated through taguchi technique was used to perform experiments based on L27 orthogonal array. The developed ANOVA and regression equations are used to find the optimum coefficient of friction and wear under the influence of applied load, sliding speed and sliding distance. On the basis of “smaller the best” the dry sliding wear resistance was analysed and finally confirmation tests were carried out to verify the experimental results.

Keywords: analysis of variance, dry sliding wear, hybrid composite, orthogonal array, Taguchi technique

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Authors: Jing-Fung Lin, Jer-Jia Sheu

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In this study, an approach has been developed for the noise reduction of a muffler. The transmission loss (TL) in the muffler is maximized by the use of a double-chamber muffler, and a baffle with a hole is inserted between chambers. Taguchi method is used to optimize the design for the acoustical performance of the muffler. The TL performance is evaluated by COMSOL software. The excellent parameter combination for the maximum TL is attained as high as 35.30 dB in a wide frequency range from 10 Hz to 1400 Hz. The influence sequence of four parameters on TL is determined by the range analysis. The effects of length and expansion ratio of the first chamber on TL performance for the excellent program were discussed. Comparisons of the TL results from different designs are made.

Keywords: acoustics, baffle, chamber, muffler, Taguchi method, transmission loss

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Authors: A. D. Parekh

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The present work describes relative contributions of operating parameters on required heat transfer area of three heat exchangers viz. evaporator, condenser and cascade condenser of two stage R404A-R508B cascade refrigeration system using Taguchi method. The operating parameters considered in present study includes (1) condensing temperature of high temperature cycle and low temperature cycle (2) evaporating temperature of low temperature cycle (3) degree of superheating in low temperature cycle (4) refrigerating effect. Heat transfer areas of three heat exchangers are studied with variation of above operating parameters and also optimum working levels of each operating parameter has been obtained for minimum heat transfer area of each heat exchanger using Taguchi method. The analysis using Taguchi method reveals that evaporating temperature of low temperature cycle and refrigerating effect contribute relatively largely on the area of evaporator. Condenser area is mainly influenced by both condensing temperature of high temperature cycle and refrigerating effect. Area of cascade condenser is mainly affected by refrigerating effect and the effects of other operating parameters are minimal.

Keywords: cascade refrigeration system, Taguchi method, heat transfer area, ANOVA, optimal solution

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Authors: A. D. Parekh

Abstract:

The present work describes relative contributions of operating parameters on required heat transfer area of three heat exchangers viz. evaporator, condenser and cascade condenser of two stage R404A-R508B cascade refrigeration system using Taguchi method. The operating parameters considered in present study includes (1) condensing temperature of high temperature cycle and low temperature cycle (2) evaporating temperature of low temperature cycle (3) degree of superheating in low temperature cycle (4) refrigerating effect. Heat transfer areas of three heat exchangers are studied with variation of above operating parameters and also optimum working levels of each operating parameter has been obtained for minimum heat transfer area of each heat exchanger using Taguchi method. The analysis using Taguchi method reveals that evaporating temperature of low temperature cycle and refrigerating effect contribute relatively largely on the area of evaporator. Condenser area is mainly influenced by both condensing temperature of high temperature cycle and refrigerating effect. Area of cascade condenser is mainly affected by refrigerating effect and the effects of other operating parameters are minimal.

Keywords: cascade refrigeration system, Taguchi method, heat transfer area, ANOVA, optimal solution

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Authors: Joseph C. Chen, Joshua Cox

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This research focuses on the use of the Taguchi method to reduce the surface roughness and improve dimensional accuracy of parts machined by Wire Electrical Discharge Machining (EDM) with S7 heat treated steel material. Due to its high impact toughness, the material is a candidate for a wide variety of tooling applications which require high precision in dimension and desired surface roughness. This paper demonstrates that Taguchi Parameter Design methodology is able to optimize both dimensioning and surface roughness successfully by investigating seven wire-EDM controllable parameters: pulse on time (ON), pulse off time (OFF), servo voltage (SV), voltage (V), servo feed (SF), wire tension (WT), and wire speed (WS). The temperature of the water in the Wire EDM process is investigated as the noise factor in this research. Experimental design and analysis based on L₁₈ Taguchi orthogonal arrays are conducted. This paper demonstrates that the Taguchi-based system enables the wire EDM process to produce (1) high precision parts with an average of 0.6601 inches dimension, while the desired dimension is 0.6600 inches; and (2) surface roughness of 1.7322 microns which is significantly improved from 2.8160 microns.

Keywords: Taguchi Parameter Design, surface roughness, Wire EDM, dimensional accuracy

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Authors: Ashish Ankus Yerunkar, Ravi Terkar

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Study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on reduction of cutting tool flank wear, because reduction in flank wear ensures increase in tool life. The predicted optimal setting ensured minimization of surface roughness. Purpose of this paper is focused on the analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method. Design for the experiment was done using Taguchi method and 18 experiments were designed by this process and experiments conducted. The results are analyzed using ANOVA method. Taguchi method has depicted that the depth of cut has significant role to play in producing lower surface roughness followed by feed. The Cutting speed has lesser role on surface roughness from the tests. The vibrations of the machine tool, tool chattering are the other factors which may contribute poor surface roughness to the results and such factors ignored for analyses. The inferences by this method will be useful to other researches for similar type of study and may be vital for further research on tool vibrations, cutting forces etc.

Keywords: surface roughness (ra), machining, dry turning, taguchi method, turning process, anova method, mahr perthometer

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Authors: Fatemeh Sadat Miri, Morteza Ehsani, Seyed Farshid Hosseini

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The present research is concerned with the optimization of extrusion parameters of ABS sheets by the Taguchi experimental design method. In this design method, three parameters of % recycling ABS, processing temperature and degassing time on mechanical properties, hardness, HDT, and color matching of ABS sheets were investigated. The variations of this research are the dosage of recycling ABS, processing temperature, and degassing time. According to experimental test data, the highest level of tensile strength and HDT belongs to the sample with 5% recycling ABS, processing temperature of 230°C, and degassing time of 3 hours. Additionally, the minimum level of MFI and color matching belongs to this sample, too. The present results are in good agreement with the Taguchi method. Based on the outcomes of the Taguchi design method, degassing time has the most effect on the mechanical properties of ABS sheets.

Keywords: ABS, process optimization, Taguchi, mechanical properties

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Authors: Gamze Karanfil Celep, Kevser Dincer

Abstract:

The effects of polymer concentration and electrospinning process parameters on the average diameters of electrospun polyacrylonitrile (PAN) nanofibers were experimentally investigated. Besides, mechanical and thermal properties of PAN nanofibers were examined by tensile test and thermogravimetric analysis (TGA), respectively. For this purpose, the polymer concentration, solution feed rate, supply voltage and tip-to-collector distance were determined as the control factors. To succeed these aims, Taguchi’s L16 orthogonal design (4 parameters, 4 level) was employed for the experimental design. Optimal electrospinning conditions were defined using the signal-to-noise (S/N) ratio that was calculated from diameters of the electrospun PAN nanofibers according to "the-smaller-the-better" approachment. In addition, analysis of variance (ANOVA) was evaluated to conclude the statistical significance of the process parameters. The smallest diameter of PAN nanofibers was observed. According to the S/N ratio response results, the most effective parameter on finding out of nanofiber diameter was determined. Finally, the Taguchi design of experiments method has been found to be an effective method to statistically optimize the critical electrospinning parameters used in nanofiber production. After determining the optimum process parameters of nanofiber production, electrical conductivity and fuel cell performance of electrospun PAN nanofibers on the carbon papers will be evaluated.

Keywords: nanofiber, electrospinning, polyacrylonitrile, Taguchi method

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Authors: G. Rajyalakhmi, C. Karthik, Gerson Desouza, Rimmie Duraisamy

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In this present work, metal matrix composites with combination of aluminium with (Sic/Al2O3) were fabricated using stir casting technique. The objective of the present work is to optimize the process parameters of Wire Electric Discharge Machining (WEDM) composites. Pulse ON Time, Pulse OFF Time, wire feed and sensitivity are considered as input process parameters with responses Material Removal Rate (MRR), Surface Roughness (SR) for optimization of WEDM process. Taguchi L18 Orthogonal Array (OA) is used for experimentation. Grey Relational Analysis (GRA) is coupled with Taguchi technique for multiple process parameters optimization. ANOVA (Analysis of Variance) is used for finding the impact of process parameters individually. Finally confirmation experiments were carried out to validate the predicted results.

Keywords: parametric optimization, particulate reinforced metal matrix composites, Taguchi-grey relational analysis, WEDM

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Authors: Kyoungwoo Park, Gil Dong Kim, Seong Joon Moon, Ho Kil Lee

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The Urea-SCR is one of the most efficient technologies to reduce NOx emissions in diesel engines. In the present work, the computational prediction of internal flow and spray characteristics in the Urea-SCR system was carried out by using 3D-CFD simulation to evaluate NH3 uniformity index (NH3 UI) and its activation time according to the official New European Driving Cycle (NEDC). The number of nozzle and its diameter, two types of injection directions, and penetration length were chosen as the design variables. The optimal solutions were obtained by coupling the CFD analysis with Taguchi method. The L16 orthogonal array and small-the-better characteristics of the Taguchi method were used, and the optimal values were confirmed to be valid with 95% confidence and 5% significance level through analysis of variance (ANOVA). The results show that the optimal solutions for the NH3 UI and activation time (NH3 UI 0.22) are obtained by 0.41 and 0,125 second, respectively, and their values are improved by 85.0% and 10.7%, respectively, compared with those of the base model.

Keywords: computational fluid dynamics, NH3 uniformity index, optimization, Taguchi method, Urea-SCR system, UWS injector

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Authors: Siamak Ghorbani, Nikolay Ivanovich Polushin

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Chatter vibrations, occurring during cutting process, cause vibration between the cutting tool and workpiece, which deteriorates surface roughness and reduces tool life. The purpose of this study is to investigate the influence of cutting parameters and tool construction on surface roughness and vibration in turning of aluminum alloy AA2024. A new design of cutting tool is proposed, which is filled up with epoxy granite in order to improve damping capacity of the tool. Experiments were performed at the lathe using carbide cutting insert coated with TiC and two different cutting tools made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to design of experiment and to optimize cutting conditions. By the help of signal-to-noise ratio and analysis of variance the optimal cutting condition and the effect of the cutting parameters on surface roughness and vibration were determined. Effectiveness of Taguchi method was verified by confirmation test. It was revealed that new cutting tool with epoxy granite has reduced vibration and surface roughness due to high damping properties of epoxy granite in toolholder.

Keywords: ANOVA, damping capacity, surface roughness, Taguchi method, vibration

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Authors: Anjian Chen, Joseph C. Chen

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This paper studies a case where the targeted surface roughness of fused deposition modeling (FDM) additive manufacturing process is improved. The process is designing to reduce or eliminate the defects and improve the process capability index Cp and Cpk for an FDM additive manufacturing process. The baseline Cp is 0.274 and Cpk is 0.654. This research utilizes the Taguchi methodology, to eliminate defects and improve the process. The Taguchi method is used to optimize the additive manufacturing process and printing parameters that affect the targeted surface roughness of FDM additive manufacturing. The Taguchi L9 orthogonal array is used to organize the parameters' (four controllable parameters and one non-controllable parameter) effectiveness on the FDM additive manufacturing process. The four controllable parameters are nozzle temperature [°C], layer thickness [mm], nozzle speed [mm/s], and extruder speed [%]. The non-controllable parameter is the environmental temperature [°C]. After the optimization of the parameters, a confirmation print was printed to prove that the results can reduce the amount of defects and improve the process capability index Cp from 0.274 to 1.605 and the Cpk from 0.654 to 1.233 for the FDM additive manufacturing process. The final results confirmed that the Taguchi methodology is sufficient to improve the surface roughness of FDM additive manufacturing process.

Keywords: additive manufacturing, fused deposition modeling, surface roughness, six-sigma, Taguchi method, 3D printing

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Authors: Suha K. Shihab, Zahid A. Khan, Aas Mohammad, Arshad Noor Siddiquee

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This paper presents the influence of cutting parameters (cutting speed, feed and depth of cut) on flank wear (VB) in turning of 52100 hard alloy steel using multilayer coated carbide insert under dry condition. Nine experiments were performed based on Taguchi’s L9 orthogonal array. Analysis of variance (ANOVA) was used to determine the effects of the cutting parameters on flank wear. The results of the study revealed that the cutting speed (A) and feed rate (B) are the dominant factors affecting flank wear, while the depth of cut (C) has not a significant effect. The optimal combination of the cutting parameters for flank wear is found to be A1B1C1. The mathematical model for flank wear is found to be statistically significant. The predicted and measured values of flank wear are found to be very close to each other.

Keywords: flank wear, hard turning, Taguchi approach, optimization

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Authors: Hari Singh, Abhishek Kamboj, Sudhir Kumar

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This investigation proposes a grey-based Taguchi method to solve the multi-response problems. The grey-based Taguchi method is based on the Taguchi’s design of experimental method, and adopts Grey Relational Analysis (GRA) to transfer multi-response problems into single-response problems. In this investigation, an attempt has been made to optimize the drilling process parameters considering weighted output response characteristics using grey relational analysis. The output response characteristics considered are surface roughness, burr height and hole diameter error under the experimental conditions of cutting speed, feed rate, step angle, and cutting environment. The drilling experiments were conducted using L27 orthogonal array. A combination of orthogonal array, design of experiments and grey relational analysis was used to ascertain best possible drilling process parameters that give minimum surface roughness, burr height and hole diameter error. The results reveal that combination of Taguchi design of experiment and grey relational analysis improves surface quality of drilled hole.

Keywords: metal matrix composite, drilling, optimization, step drill, surface roughness, burr height, hole diameter error

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Authors: Navajyoti Panda, R. S. Pawar

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In this study, process parameters like punch angle, die opening, grain direction, and pre-bend condition of the strip for deep draw of high strength low alloy steel HSLA 420 are investigated. The finite element method (FEM) in association with the Taguchi and the analysis of variance (ANOVA) techniques are carried out to investigate the degree of importance of process parameters in V-bending process for HSLA 420&ST12 grade material. From results, it is observed that punch angle had a major influence on the spring-back. Die opening also showed very significant role on spring back. On the other hand, it is revealed that grain direction had the least impact on spring back; however, if strip from flat sheet is taken, then it is less prone to spring back as compared to the strip from sheet metal coil. HyperForm software is used for FEM simulation and experiments are designed using Taguchi method. Percentage contribution of the parameters is obtained through the ANOVA techniques.

Keywords: bending, spring-back, v-bending, FEM, Taguchi, HSLA 420 and St12 materials, HyperForm, profile projector

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Authors: Mearg Berhe Gebregziabher

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Wire-cut electric discharge machining (WEDM) is one of the advanced machining processes. Due to the development of the current manufacturing sector, there has been no research work done before about the optimization of the process parameters based on the availability of the workpiece of the Steel St-37 material in Ethiopia. Material Removal Rate (MRR) is considered as the experimental response of WCEDM. The main objective of this work is to investigate and optimize the process parameters on machining quality that gives high MRR during machining of Steel St-37. Throughout the investigation, Pulse on Time (TON), Pulse off Time (TOFF) and Velocities of Wire Feed (WR) are used as variable parameters at three different levels, and Wire tension, flow rate, type of dielectric fluid, type of the workpiece and wire material and dielectric flow rate are keeping as constants for each experiment. The Taguchi methodology, as per Taguchi‟ 's standard L9 (3^3) Orthogonal Array (OA), has been carried out to investigate their effects and to predict the optimal combination of process parameters over MRR. Signal to Noise ratio (S/N) and Analysis of Variance (ANOVA) were used to analyze the effect of the parameters and to identify the optimum cutting parameters on MRR. MRR was measured by using the Electronic Balance Model SI-32. The results indicated that the most significant factors for MRR are TOFF, TON and lastly WR. Taguchi analysis shows that, the optimal process parameters combination is A2B2C2, i.e., TON 6μs, TOFF 29μs and WR 2 m/min. At this level, the MRR of 0.414 gram/min has been achieved.

Keywords: ANOVA, MRR, parameter, Taguchi Methode

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Authors: Weinian Wang, Joseph C. Chen

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The objective of this research is to optimize the process of cutting cylindrical workpieces utilizing live tooling on a HAAS ST-20 lathe. Surface roughness (Ra) has been investigated as the indicator of quality characteristics for machining process. Aluminum alloy was used to conduct experiments due to its wide range usages in engineering structures and components where light weight or corrosion resistance is required. In this study, Taguchi methodology is utilized to determine the effects that each of the parameters has on surface roughness (Ra). A total of 18 experiments of each process were designed according to Taguchi’s L9 orthogonal array (OA) with four control factors at three levels of each and signal-to-noise ratios (S/N) were computed with Smaller the better equation for minimizing the system. The optimal parameters identified for the surface roughness of the turning operation utilizing live tooling were a feed rate of 3 inches/min(A3); a spindle speed of 1300 rpm(B3); a 2-flute titanium nitrite coated 3/8” endmill (C1); and a depth of cut of 0.025 inches (D2). The mean surface roughness of the confirmation runs in turning operation was 8.22 micro inches. The final results demonstrate that Taguchi methodology is a sufficient way of process improvement in turning process on surface roughness.

Keywords: CNC milling operation, CNC turning operation, surface roughness, Taguchi parameter design

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Authors: S. Heydari, H. Sharififard, M. Nabavinia, H. Kiani, M. Parvizi

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Rapid industrialization has led to increased disposal of heavy metals into the environment. Activated carbon adsorption has proven to be an effective process for the removal of trace metal contaminants from aqueous media. This paper was investigated chromium adsorption efficiency by commercial activated carbon. The sorption studied as a function of activated carbon particle size, dose of activated carbon and initial pH of solution. Adsorption tests for the effects of these factors were designed with Taguchi approach. According to the Taguchi parameter design methodology, L9 orthogonal array was used. Analysis of experimental results showed that the most influential factor was initial pH of solution. The optimum conditions for chromium adsorption by activated carbons were found to be as follows: Initial feed pH 6, adsorbent particle size 0.412 mm and activated carbon dose 6 g/l. Under these conditions, nearly %100 of chromium ions was adsorbed by activated carbon after 2 hours.

Keywords: chromium, adsorption, Taguchi method, activated carbon

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