Search results for: taguchi analysis

Authors: Charles Chikwendu Okpala, Christopher Chukwutoo Ihueze

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As a technique that reduces variation in a product by lessening the sensitivity of the design to sources of variation, rather than by controlling their sources, Taguchi Robust Design entails the designing of ideal goods, by developing a product that has minimal variance in its characteristics and also meets the desired exact performance. This paper examined the concept of the manufacturing approach and its application to brake pad product of an automotive parts manufacturing company. Although the firm claimed that only defects, excess inventory, and over-production were the few wastes that grossly affect their productivity and profitability, a careful study and analysis of their manufacturing processes with the application of Single Minute Exchange of Dies (SMED) tool showed that the waste of waiting is the fourth waste that bedevils the firm. The selection of the Taguchi L9 orthogonal array which is based on the four parameters and the three levels of variation for each parameter revealed that with a range of 2.17, that waiting is the major waste that the company must reduce in order to continue to be viable. Also, to enhance the company’s throughput and profitability, the wastes of over-production, excess inventory, and defects with ranges of 2.01, 1.46, and 0.82, ranking second, third, and fourth respectively must also be reduced to the barest minimum. After proposing -33.84 as the highest optimum Signal-to-Noise ratio to be maintained for the waste of waiting, the paper advocated for the adoption of all the tools and techniques of Lean Production System (LPS), and Continuous Improvement (CI), and concluded by recommending SMED in order to drastically reduce set up time which leads to unnecessary waiting.

Keywords: lean production system, single minute exchange of dies, signal to noise ratio, Taguchi robust design, waste

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Authors: Gurjeet Singh, M. K. Pradhan, Ajay Verma

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The plastic industry plays very important role in the economy of any country. It is generally among the leading share of the economy of the country. Since metals and their alloys are very rarely available on the earth. So to produce plastic products and components, which finds application in many industrial as well as household consumer products is beneficial. Since 50% plastic products are manufactured by injection moulding process. For production of better quality product, we have to control quality characteristics and performance of the product. The process parameters plays a significant role in production of plastic, hence the control of process parameter is essential. In this paper the effect of the parameters selection on injection moulding process has been described. It is to define suitable parameters in producing plastic product. Selecting the process parameter by trial and error is neither desirable nor acceptable, as it is often tends to increase the cost and time. Hence optimization of processing parameter of injection moulding process is essential. The experiments were designed with Taguchi’s orthogonal array to achieve the result with least number of experiments. Here Plastic material polypropylene is studied. Tensile strength test of material is done on universal testing machine, which is produced by injection moulding machine. By using Taguchi technique with the help of MiniTab-14 software the best value of injection pressure, melt temperature, packing pressure and packing time is obtained. We found that process parameter packing pressure contribute more in production of good tensile plastic product.

Keywords: injection moulding, tensile strength, poly-propylene, Taguchi

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Authors: Ajay Biswas, Swapan Bhaumik, Abhijit Bhowmik

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Present experiment has been carried out to study the microstructure of weldment obtained by submerged arc welding on mild steel plate at zero degree Celsius. To study this, bead on plate welding is done by submerged arc welding on the sample plate of heavy duty mild steel of designation IS 2062 grade B, fitted on the special fixture ensuring the plate temperature at zero degree Celsius. Sixteen numbers of such samples are welded by varying the most influencing parameters viz. travel speed, voltage, wire feed rate and electrode stick-out at four different levels. Taguchi’s design of experiment is applied by selecting Taguchi's L16 orthogonal array to restrict the number of experimental runs. Cross sectioned samples are polished and etched to view the weldment. Finally, different zone of the weldment is observed by optical microscope. From the type of microstructure of weldment it is concluded that submerged arc welding is feasible at zero degree Celsius on mild steel plate.

Keywords: Submerged Arc Welding, zero degree Celsius, Taguchi’s design of experiment, microstructure of weldment

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Authors: D. Kari Basavaraja, M. G. Skanda, C. Soumya, V. Ramesh

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This paper discusses the effects of sodium hypophosphite concentration, pH, and temperature on deposition rate. This paper also discusses the evaluation of coating strength, surface, and subsurface by varying the bath parameters, percentage of phosphate, plating temperature, and pH of the plating solution. Taguchi technique has been used for the analysis. In the experiment, nickel chloride which is a source of nickel when mixed with sodium hypophosphite has been used as the reducing agent and the source of phosphate and sodium hydroxide has been used to vary the pH of the coating bath. The coated samples are tested for impact energy by conducting impact test. Finally, the effects of coating bath parameters on the impact energy absorbed have been plotted, and analysis has been carried out. Further, percentage contribution of coating bath parameters using Design of Experiments approach (DOE) has been analysed. Finally, it can be concluded that the bath parameters of the Ni-P coating will certainly influence on the strength of the specimen.

Keywords: bath parameters, coatings, design of experiment, fracture toughness, impact strength

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Authors: Amitesh Goswami, Vishal Gulati, Annu Yadav

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In this paper, WEDM has been used to investigate the machining characteristics of Inconel-625 alloy. The machining characteristics namely material removal rate (MRR) and surface roughness (SR) have been investigated along with surface microstructure analysis using SEM and EDS of the machined surface. Taguchi’s L27 Orthogonal array design has been used by considering six varying input parameters viz. Pulse-on time (Ton), Pulse-off time (Toff), Spark Gap Set Voltage (SV), Peak Current (IP), Wire Feed (WF) and Wire Tension (WT) for the responses of interest. It has been found out that Pulse-on time (Ton) and Spark Gap Set Voltage (SV) are the most significant parameters affecting material removal rate (MRR) and surface roughness (SR) are. Microstructure analysis of workpiece was also done using Scanning Electron Microscope (SEM). It was observed that, variations in pulse-on time and pulse-off time causes varying discharge energy and as a result of which deep craters / micro cracks and large/ small number of debris were formed. These results were helpful in studying the effects of pulse-on time and pulse-off time on MRR and SR. Energy Dispersive Spectrometry (EDS) was also done to check the compositional analysis of the material and it was observed that Copper and Zinc which were initially not present in the Inconel 625, later migrated on the material surface from the brass wire electrode during machining

Keywords: MRR, SEM, SR, taguchi, Wire Electric Discharge Machining

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Authors: E. Behmanesh, J. Pannek

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Logistics network design is known as one of the strategic decision problems. As these kinds of problems belong to the category of NP-hard problems, traditional ways are failed to find an optimal solution in short time. In this study, we attempt to involve reverse flow through an integrated design of forward/reverse supply chain network that formulated into a mixed integer linear programming. This Integrated, multi-stages model is enriched by three different delivery path which makes the problem more complex. To tackle with such an NP-hard problem a revised random path direct encoding method based memetic algorithm is considered as the solution methodology. Each algorithm has some parameters that need to be investigate to reveal the best performance. In this regard, Taguchi method is adapted to identify the optimum operating condition of the proposed memetic algorithm to improve the results. In this study, four factors namely, population size, crossover rate, local search iteration and a number of iteration are considered. Analyzing the parameters and improvement in results are the outlook of this research.

Keywords: integrated logistics network, flexible path, memetic algorithm, Taguchi method

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Authors: Shraddha Digole, Swarali Hingse, Uday Annapure

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Mycophenolic acid (MPA) is an immunosuppressant; produced by Penicillium Sp. Box-Behnken statistical experimental design was employed to optimize the condition of Penicillium brevicompactum NRRL 2011 for mycophenolic acid (MPA) production. Initially optimization of various physicochemical parameters and media components was carried out using one factor at a time approach and significant factors were screened by Taguchi L-16 orthogonal array design. Taguchi design indicated that glucose, KH2PO4 and MgSO4 had significant effect on MPA production. These variables were selected for further optimization studies using Box-Behnken design. Optimised fermentation condition, glucose (60 g/L), glycine (28 g/L), L-leucine (1.5g/L), KH2PO4 (3g/L), MgSO4.7H2O (1.5g/L), increased the production of MPA from 170 mg/L to 1032.54 mg/L. Analysis of variance (ANOVA) showed a high value of coefficient of determination R2 (0.9965), indicating a good agreement between experimental and predicted values and proves validity of the statistical model.

Keywords: Box-Behnken design, fermentation, mycophenolic acid, Penicillium brevicompactum

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Authors: Mandeep Kumar, Hari Singh

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The effective optimization of machining process parameters affects dramatically the cost and production time of machined components as well as the quality of the final products. This paper presents the optimization aspects of a Wire Electrical Discharge Machining operation using Inconel X-750 as work material. The objective considered in this study is minimization of the dimensional deviation. Six input process parameters of WEDM namely spark gap voltage, pulse-on time, pulse-off time, wire feed rate, peak current and wire tension, were chosen as variables to study the process performance. Taguchi's design of experiments methodology has been used for planning and designing the experiments. The analysis of variance was carried out for raw data as well as for signal to noise ratio. Four input parameters and one two-factor interaction have been found to be statistically significant for their effects on the response of interest. The confirmation experiments were also performed for validating the predicted results.

Keywords: ANOVA, DOE, inconel, machining, optimization

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Authors: Mehdi Moayyedian, Kazem Abhary, Romeo Marian

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This paper presents an evaluation of a plastic defect in injection molding before it occurs in the process; it is known as the short shot defect. The evaluation of different parameters which affect the possibility of short shot defect is the aim of this paper. The analysis of short shot possibility is conducted via SolidWorks Plastics and Taguchi method to determine the most significant parameters. Finite Element Method (FEM) is employed to analyze two circular flat polypropylene plates of 1 mm thickness. Filling time, part cooling time, pressure holding time, melt temperature and gate type are chosen as process and geometric parameters, respectively. A methodology is presented herein to predict the possibility of the short-shot occurrence. The analysis determined melt temperature is the most influential parameter affecting the possibility of short shot defect with a contribution of 74.25%, and filling time with a contribution of 22%, followed by gate type with a contribution of 3.69%. It was also determined the optimum level of each parameter leading to a reduction in the possibility of short shot are gate type at level 1, filling time at level 3 and melt temperature at level 3. Finally, the most significant parameters affecting the possibility of short shot were determined to be melt temperature, filling time, and gate type.

Keywords: injection molding, plastic defects, short shot, Taguchi method

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Authors: Alae Lamtai, Said Elkoun, Hniya Kharmoudi, Mathieu Robert, Carl Diez

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This study applies Taguchi's design of experiment methodology and grey relational analysis (GRA) for multi objective optimization of an industrial recycling line. This last is composed mainly of a mono and twin-screw extruder and a filtration system. Experiments were performed according to L₁₆ standard orthogonal array based on five process parameters, namely: mono screw design, screw speed of the mono and twin-screw extruder, melt pump pressure, and filter mesh size. The objective of this optimization is to improve the durability of the Polyethylene (PE) blend by decreasing the loss of Stress Crack resistance (SCR) using Notched Crack Ligament Stress (NCLS) test and Unnotched Crack Ligament Stress (UCLS) in parallel with increasing the gain of Izod impact strength of the Polyethylene (PE) blend before and after recycling. Based on Grey Relational Analysis (GRA), the optimal setting of process parameters was identified, and the results indicated that the mono-screw design and screw speed of both mono and twin-screw extruder impact significantly the mechanical properties of recycled Polyethylene (PE) blend.

Keywords: Taguchi, recycling line, polyethylene, stress crack resistance, Izod impact strength, grey relational analysis

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Authors: Abdolreza Heidari Noosh Abad, Amir Abedi, Davood Mirahmadi khaki

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The high strength and flexibility of TRIP steels are the major reasons for them being widely used in the automobile industry. Deep drawing is regarded as a common metal sheet manufacturing process is used extensively in the modern industry, particularly automobile industry. To investigate the potential of deep drawing characteristic of materials, steel sheet anisotropy is studied and expressed as R-Value. The TRIP steels have a multi-phase microstructure consisting typically of ferrite, bainite and retained austenite. The retained austenite appears to be the most effective phase in the microstructure of the TRIP steels. In the present research, Taguchi method has been employed to study investigates the effect of austempering temperature parameters on the anisotropy property of the TRIP steel. To achieve this purpose, a steel with chemical composition of 0.196C -1.42Si-1.41Mn, has been used and annealed at 810oC, and then austempered at 340-460oC for 3, 6, and 9 minutes. The results shows that the austempering temperature has a direct relationship with R-value, respectively. With increasing austempering temperature, residual austenite grain size increases as well as increased solubility, which increases the amount of R-value. According to the results of the Taguchi method, austempering temperature’s p-value less than 0.05 is due to effective on R-value.

Keywords: Taguchi method, hot rolling, thermomechanical process, anisotropy, R-value

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Authors: Mu-Yen Chen, Min-Hsuan Fan, Chia-Chen Chen, Siang-Yu Jhong

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In recent years, real estate prediction or valuation has been a topic of discussion in many developed countries. Improper hype created by investors leads to fluctuating prices of real estate, affecting many consumers to purchase their own homes. Therefore, scholars from various countries have conducted research in real estate valuation and prediction. With the back-propagation neural network that has been popular in recent years and the orthogonal array in the Taguchi method, this study aimed to find the optimal parameter combination at different levels of orthogonal array after the system presented different parameter combinations, so that the artificial neural network obtained the most accurate results. The experimental results also demonstrated that the method presented in the study had a better result than traditional machine learning. Finally, it also showed that the model proposed in this study had the optimal predictive effect, and could significantly reduce the cost of time in simulation operation. The best predictive results could be found with a fewer number of experiments more efficiently. Thus users could predict a real estate transaction price that is not far from the current actual prices.

Keywords: artificial neural network, Taguchi method, real estate valuation model, investors

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Authors: M. S. Said, J. A. Ghani, Izzati Osman, Z. A. Latiff, S. A .F. Syed Mohd

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Metal matrix composites have demand for light-weight structural and functional materials. MMCs have been shown to offer improvements in strength, rigidity, temperature stability, wear resistance, reliability and control of physical properties such as density and coefficient of thermal expansion, thereby providing improved engineering performance in comparison to the un-reinforced matrix. Experiment were conducted at various cutting speed, feed rate and difference cutting tools according to Taguchi method using a standard orthogonal array L9. The volume of AlN reinforced particle was 10% in MMC. The milling process was carried out under dry cutting condition using uncoated carbide, TiN and TiCN tool insert. The parameters used were the cutting speed of (230,300,370 m/min) the federate used were (0.4, 0.6, 0.8 mm/tooth) while the depth of cut is constant (0.3 mm). The tool diameter is 20mm. From the project, the surface roughness mechanism was investigated in detail using Mitutoyo portable surface roughness measurements surftest SJ-310. This machining will be fabricated on MMC with 150mm length, 100mm width and 30mm thick. The results showed using S/N ratio, concluded that a combination of low cutting speed, medium feed rate and uncoated insert give a remarkable surface finish. From the ANOVA result showed the feed rate was major contributing factor (43.76%) following type of insert (40.89%).

Keywords: MMC, milling operation and surface roughness, Taguchi method

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Authors: Reza Vakili

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The aim of this experiment was to optimize the effect of moisture, the production rate, grain particle size and steam conditioning temperature on pellet quality in broiler feed using Taguchi method and a 43 fractional factorial arrangement was conducted. Production rate, steam conditioning temperatures, particle sizes and moisture content were performed. During the production process, sampling was done, and then pellet durability index (PDI) and hardness evaluated in broiler feed grower and finisher. There was a significant effect of processing parameters on PDI and hardness. Based on the results of this experiment Taguchi method can be used to find the best combination of factors for optimal pellet quality.

Keywords: broiler, feed physical quality, hardness, processing parameters, PDI

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Authors: Ahmed A. D. Sarhan, Hong Wan Ping, M. Sayuti

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In this current era of competitive machinery productions, the industries are designed to place more emphasis on the product quality and reduction of cost whilst abiding by the pollution-preventing policy. In attempting to delve into the concerns, the industries are aware that the effectiveness of existing lubrication systems must be improved to achieve power-efficient and pollution-preventing machining processes. As such, this research is targeted to study on a plausible solution to the issue in grinding titanium alloy (Ti-6Al-4V) by using nanolubrication, as an alternative to flood grinding. The aim of this research is to evaluate the optimum condition of grinding force and surface roughness using MQL lubricating system to deliver nano-oil at different level of weight concentration of Silicon Dioxide (SiO2) mixed normal mineral oil. Taguchi Design of Experiment (DoE) method is carried out using a standard Taguchi orthogonal array of L16(43) to find the optimized combination of weight concentration mixture of SiO2, nozzle orientation and pressure of MQL. Surface roughness and grinding force are also analyzed using signal-to-noise(S/N) ratio to determine the best level of each factor that are tested. Consequently, the best combination of parameters is tested for a period of time and the results are compared with conventional grinding method of dry and flood condition. The results show a positive performance of MQL nanolubrication.

Keywords: grinding, MQL, precision grinding, Taguchi optimization, titanium alloy

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Authors: Mehmet Erdi Korkmaz, Mustafa Günay

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Nowadays, grinding is frequently replaced with hard turning for reducing set up time and higher accuracy. This paper focused on mathematical modeling of average surface roughness (Ra) in hard turning of AISI L2 grade (DIN 1.2210) cold work tool steel with ceramic tools. The steel was hardened to 60±1 HRC after the heat treatment process. Cutting speed, feed rate, depth of cut and tool nose radius was chosen as the cutting conditions. The uncoated ceramic cutting tools were used in the machining experiments. The machining experiments were performed according to Taguchi L27 orthogonal array on CNC lathe. Ra values were calculated by averaging three roughness values obtained from three different points of machined surface. The influences of cutting conditions on surface roughness were evaluated as statistical and experimental. The analysis of variance (ANOVA) with 95% confidence level was applied for statistical analysis of experimental results. Finally, mathematical models were developed using the artificial neural networks (ANN). ANOVA results show that feed rate is the dominant factor affecting surface roughness, followed by tool nose radius and cutting speed.

Keywords: ANN, hard turning, DIN 1.2210, surface roughness, Taguchi method

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Authors: Meshal Alsaiari

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Fused Deposition Modeling is one of the additive manufacturing technologies the industry is shifting to nowadays due to its simplicity and low affordable cost. The fabrication processing parameters predominantly influence FDM part strength and mechanical properties. This presentation will demonstrate the influences of the two manufacturing parameters on the tensile testing evaluation indexes, infill density, and Printing Orientation, which were analyzed to create a piping spacer suitable for oil and gas applications. The tensile specimens are made of two polymers, Acrylonitrile Styrene Acrylate (ASA) and High high-impact polystyrene (HIPS), to characterize the mechanical properties performance for creating the final product. The mechanical testing was carried out per the ASTM D638 testing standard, following Type IV requirements. Taguchi's experiment design using an L-9 orthogonal array was used to evaluate the performance output and identify the optimal manufacturing factors. The experimental results demonstrate that the tensile test is more pronounced with 100% infill for ASA and HIPS samples. However, the printing orientations varied in reactions; ASA is maximum at 0 degrees while HIPS shows almost similar percentages between 45 and 90 degrees. Taguchi-Gray integrated methodology was adopted to minimize the response and recognize optimal fabrication factors combinations.

Keywords: FDM, ASTM D638, tensile testing, acrylonitrile styrene acrylate

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Authors: Lingaraju Dumpala, Narasa Raju Gosangi

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Friction Stir Welding (FSW) is relatively new, environmentally friendly, versatile, and widely used joining technique for soft materials such as aluminum. FSW has got a lot of attention as a solid-state joining method which avoids many common problems of fusion welding and provides an improved way of producing aluminum joints in a faster way. FSW can be used for various aerospace, defense, automotive and transportation applications. It is necessary to understand the friction stir welded joints and its characteristics to use this new joining technique in critical applications. This study investigated the mechanical properties of friction stir welded aluminum 6063 alloys. FSW is carried out based on the design of experiments using L16 mixed level array by considering tool rotational speeds, tool feed rate and tool tilt angles as process parameters. The optimization of process parameters is carried by Taguchi based regression analysis and the significance of process parameters is analyzed using ANOVA. It is observed that the considered process parameters are high influences the mechanical properties of Al6063.

Keywords: FSW, aluminum alloy, mechanical properties, optimization, Taguchi, ANOVA

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Authors: Evln Ranga Charyulu, S. P. Venu Madhavarao, S. Udaya kumar, S. V. S. S. N. V. G. Krishna Murthy

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With the advent of new nanometer process technologies, it is possible to integrate billion transistors on a single substrate. When more and more functionality included there is the possibility of multi-million transistors switching simultaneously consuming more power and dissipating more power along with more leakage of current into the substrate of porous silicon or germanium material. These results in substrate heating and thermal noise generation coupled to signals of interest. The heating process is represented by coupled nonlinear partial differential equations in porous silicon and germanium. By identifying heat sources and heat fluxes may results in designing of ultra-low power circuits. The PDEs are solved by finite difference scheme assuming that boundary layer equations in porous silicon and germanium. Local heat fluxes along the vertical isothermal surface immersed in porous SI/Ge are considered. The parameters considered for optimization are thermal diffusivity, thermal expansion coefficient, thermal diffusion ratio, permeability, specific heat at constant temperatures, Rayleigh number, amplitude of wavy surface, mass expansion coefficient. The diffusion of heat was caused by the concentration gradient. Thermal physical properties are homogeneous and isotropic. By using L8, TAGUCHI method the parameters are optimized.

Keywords: heat transfer, pde, taguchi optimization, SI/Ge

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Authors: M. Unaldi, R. Kus

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Brake pads are important parts of the braking system and they are made of different materials. Use of asbestos fibre can cause health risks. The goal of this study is to determine the effect of ecological brake pad samples which are produced under different compaction pressure values and mixture ratios by using miscanthus as reinforcement component on the density, hardness, wear rate and compression strength properties, and friction coefficients changes of ecological brake pad samples. Miscanthus powder, cashew powder, alumina powder, phenolic resin powder, and calcite powder mixtures were used to produce ecological brake pad samples. The physical properties of the brake pad samples produced under different mixture ratios and compaction pressures values were determined to assign their effects on them by using Taguchi experimental design. Mixture ratios and compaction pressures values were chosen as the factors with three-levels. Experiments are conducted to L₉(3⁴) Taguchi orthogonal array design. The results showed that hardness value is very much affected both compaction pressure values and mixture ratios than the other physical properties. When reinforcing component ratio within the mixture and compaction pressure value is increased, hardness and compression strength values of the all samples are also increased. All test results taking into account, the ideal compaction value for used components and mixture ratios were determined as 200 MPa.

Keywords: brake pad, eco-friendly materials, hardness, Miscanthus, Taguchi method

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Authors: Won Jung, Wan Emri

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Ferrite magnet is widely used in many automotive components such as motors and alternators. Magnets used inside the components must be in good quality to ensure the high level of performance. The purpose of this study is to design input parameters that optimize the ferrite magnet production process to ensure the quality and reliability of manufactured products. Design of Experiments (DOE) and Statistical Process Control (SPC) are used as mutual supplementations to optimize the process. DOE and SPC are quality tools being used in the industry to monitor and improve the manufacturing process condition. These tools are practically used to maintain the process on target and within the limits of natural variation. A mixed Taguchi method is utilized for optimization purpose as a part of DOE analysis. SPC with proportion data is applied to assess the output parameters to determine the optimal operating conditions. An example of case involving the monitoring and optimization of ferrite magnet process was presented to demonstrate the effectiveness of this approach. Through the utilization of these tools, reliable magnets can be produced by following the step by step procedures of proposed framework. One of the main contributions of this study was producing the crack free magnets by applying the proposed parameter design.

Keywords: ferrite magnet, crack, reliability, process optimization, Taguchi method

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Authors: Saurabh Satija, Munish Garg

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Present work reports an efficient extraction method using microwaves based solvent–sample duo-heating mechanism, for the extraction of an important anti-diabetic plant Tinospora cordifolia from AYUSH system for estimation of berberine content. The process is based on simultaneous heating of sample matrix and extracting solvent under microwave energy. Methanol was used as the extracting solvent, which has excellent berberine solubilizing power and warms up under microwave attributable to its great dispersal factor. Extraction conditions like time of irradition, microwave power, solute-solvent ratio and temperature were optimized using Taguchi design and berberine was quantified using high performance thin layer chromatography. The ranked optimized parameters were microwave power (rank 1), irradiation time (rank 2) and temperature (rank 3). This kind of extraction mechanism under dual heating provided choice of extraction parameters for better precision and higher yield with significant reduction in extraction time under optimum extraction conditions. This developed extraction protocol will lead to extract higher amounts of berberine which is a major anti-diabetic moiety in Tinospora cordifolia which can lead to development of cheaper formulations of the plant Tinospora cordifolia and can help in rapid prevention of diabetes in the world.

Keywords: berberine, microwave, optimization, Taguchi

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Authors: P. Zamani, S. Mohajerzadeh, R. Masoudinejad, K. Farhangdoost

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The riveting process is one of the important ways to keep fastening the lap joints in aircraft structures. Failure of aircraft lap joints directly depends on the stress field in the joint. An important application of riveting process is in the construction of aircraft fuselage structures. In this paper, a 3D finite element method is carried out in order to optimize residual stress field in a riveted lap joint and also to estimate its fatigue life. In continue, a number of experiments are designed and analyzed using design of experiments (DOE). Then, Taguchi method is used to select an optimized case between different levels of each factor. Besides that, the factor which affects the most on residual stress field is investigated. Such optimized case provides the maximum residual stress field. Fatigue life of the optimized joint is estimated by Paris-Erdogan law. Stress intensity factors (SIFs) are calculated using both finite element analysis and experimental formula. In addition, the effect of residual stress field, geometry, and secondary bending are considered in SIF calculation. A good agreement is found between results of such methods. Comparison between optimized fatigue life and fatigue life of other joints has shown an improvement in the joint’s life.

Keywords: fatigue life, residual stress, riveting process, stress intensity factor, Taguchi method

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Authors: S. Ghorbani, N. I. Polushin

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The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.

Keywords: decision tree forest, GMDH, surface roughness, Taguchi method, turning process

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Authors: Ariangelo Hauer Dias Filho, Gustavo Antoniácomi de Carvalho, Benjamim de Melo Carvalho

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The work´s purpose was to evaluate the possibility of manufacturing casting tools utilizing Fused Filament Fabrication, a 3D printing technique, without any post-processing on the printed part. Taguchi Orthogonal array was used to evaluate the influence of extrusion temperature, bed temperature, layer height, and infill on the dimensional accuracy of a 3D-Printed Polymer Model. A Zeiss T-SCAN CS 3D Scanner was used for dimensional evaluation of the printed parts within the limit of ±0,2 mm. The mold capabilities were tested with the printed model to check how it would interact with the green sand. With little adjustments in the 3D model, it was possible to produce rapid tools without the need for post-processing for iron casting. The results are important for reducing time and cost in the development of such tools.

Keywords: additive manufacturing, Taguchi method, rapid tooling, fused filament fabrication, casting mold

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Authors: Nhat Linh Ho, Thanh-Phong Dao, Shyh-Chour Huang, Hieu Giang Le

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This paper presents a design and optimization for a compliant gripper. The gripper is constructed based on the concept of compliant mechanism with flexure hinge. A passive force regulation mechanism is presented to control the grasping force a micro-sized object instead of using a sensor force. The force regulation mechanism is designed using the planar springs. The gripper is expected to obtain a large range of displacement to handle various sized objects. First of all, the statics and dynamics of the gripper are investigated by using the finite element analysis in ANSYS software. And then, the design parameters of the gripper are optimized via Taguchi method. An orthogonal array L₉ is used to establish an experimental matrix. Subsequently, the signal to noise ratio is analyzed to find the optimal solution. Finally, the response surface methodology is employed to model the relationship between the design parameters and the output displacement of the gripper. The design of experiment method is then used to analyze the sensitivity so as to determine the effect of each parameter on the displacement. The results showed that the compliant gripper can move with a large displacement of 213.51 mm and the force regulation mechanism is expected to be used for high precision positioning systems.

Keywords: flexure hinge, compliant mechanism, compliant gripper, force regulation mechanism, Taguchi method, response surface methodology, design of experiment

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Authors: Sunny Arora, Meghal A. Desai

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An impetus towards green consumerism and implementation of sustainable techniques, consumption of natural products and utilization of environment friendly techniques have gained accelerated acceptance. Butein, a natural colorant, has many medicinal properties apart from its use in dyeing industries. Extraction of butein from the flowers of flame of forest was carried out using ultrasonication bath. Solid loading (2-6 g), extraction time (30-50 min), volume of solvent (30-50 mL) and types of solvent (methanol, ethanol and water) have been studied to maximize the yield of butein using the Taguchi method. The highest yield of butein 4.67% (w/w) was obtained using 4 g of plant material, 40 min of extraction time and 30 mL volume of methanol as a solvent. The present method provided a greater reduction in extraction time compared to the conventional method of extraction. Hence, the outcome of the present investigation could further be utilized to develop the method at a higher scale.

Keywords: butein, flowers of Flame of the Forest, Taguchi method, ultrasonic bath

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Authors: Ouahiba Taamallah, Tarek Litim

Abstract:

The study deals with the burnishing effect of AISI 52100 steel and parameters influence (Py, i and f on surface integrity. The results show that the optimal effects are closely related to the treatment parameters. With a 92% improvement in roughness, SB can be defined as a finishing operation within the machining range. Due to 85% gain in consolidation rate, this treatment constitutes an efficient process for work-hardening of material. In addition, a statistical study based on regression and Taguchi's design has made it possible to develop mathematical models to predict output responses according to the studied burnishing parameters. Response Surface Methodology RSM showed a simultaneous influence of the burnishing parameters and to observe the optimal parameters of the treatment. ANOVA Analysis of results led to validate the prediction model with a determination coefficient R2=94.60% and R2=93.41% for surface roughness and micro-hardness, respectively. Furthermore, a multi-objective optimization allowed to identify a regime characterized by P=20 Kgf, i=5 passes and f=0.08 mm.rev-1, which favors minimum surface roughness and a maximum of micro-hardness. The result was validated by a composite desirability D_i=1 for both surface roughness and microhardness, respectively. Applying optimal parameters, burnishing showed its beneficial effects in fatigue resistance, especially for imposed loading in the low cycle fatigue of the material where the lifespan increased by 90%.

Keywords: AISI 52100 steel, burnishing, Taguchi, fatigue

Procedia PDF Downloads 169

Authors: Swarali Hingse, Shraddha Digole, Uday Annapure

Abstract:

The present study investigates the biotransformation of ferulic acid to vanillin by Pycnoporus cinnabarinus and its optimization using one-factor-at-a-time method as well as statistical approach. Effect of various physicochemical parameters and medium components was studied using one-factor-at-a-time method. Screening of the significant factors was carried out using L25 Taguchi orthogonal array and then these selected significant factors were further optimized using response surface methodology (RSM). Significant media components obtained using Taguchi L25 orthogonal array were glucose, KH2PO4 and yeast extract. Further, a Box Behnken design was used to investigate the interactive effects of the three most significant media components. The final medium obtained after optimization using RSM containing glucose (34.89 g/L), diammonium tartrate (1 g/L), yeast extract (1.47 g/L), MgSO4•7H2O (0.5 g/L), KH2PO4 (0.15 g/L), and CaCl2•2H2O (20 mg/L) resulted in amplification of vanillin production from 30.88 mg/L to 187.63 mg/L.

Keywords: ferulic acid, pycnoporus cinnabarinus, response surface methodology, vanillin

Procedia PDF Downloads 359

Authors: Eyob Messele Sefene, Atinkut Atinafu Yilma

Abstract:

The highest strength-to-weight ratio criterion has fascinated increasing curiosity in virtually all areas where weight reduction is indispensable. One of the recent advances in manufacturing to achieve this intention endears friction stir welding (FSW). The process is widely used for joining similar and dissimilar non-ferrous materials. In FSW, the mechanical properties of the weld joints are impelled by property-selected process parameters. This paper presents verdicts of optimum process parameters in attempting to attain enhanced mechanical properties of the weld joint. The experiment was conducted on a 5 mm 6061 aluminum alloy sheet. A butt joint configuration was employed. Process parameters, rotational speed, traverse speed or feed rate, axial force, dwell time, tool material and tool profiles were utilized. Process parameters were also optimized, making use of a mixed L18 orthogonal array and the Grey relation analysis method with larger is better quality characteristics. The mechanical properties of the weld joint are examined through the tensile test, hardness test and liquid penetrant test at ambient temperature. ANOVA was conducted in order to investigate the significant process parameters. This research shows that dwell time, rotational speed, tool shape, and traverse speed have become significant, with a joint efficiency of about 82.58%. Nine confirmatory tests are conducted, and the results indicate that the average values of the grey relational grade fall within the 99% confidence interval. Hence the experiment is proven reliable.

Keywords: friction stir welding, optimization, 6061 AA, Taguchi

Procedia PDF Downloads 73