Abstract: Machining through turning was carried out in a lathe
to study the chip formation of Multiphase Ferrite
(F-B-M) microalloyed steel. Taguchi orthogonal array was employed
to perform the machining. Continuous and discontinuous chips were
formed for different cutting parameters like speed, feed and depth of
cut. Optical and scanning electron microscope was employed to
identify the chip morphology.
Abstract: The aim of this research is to evaluate surface
roughness and develop a multiple regression model for surface roughness as a function of cutting parameters during the turning of
flame hardened medium carbon steel with TiN-Al2O3-TiCN coated inserts. An experimental plan of work and signal-to-noise ratio (S/N)
were used to relate the influence of turning parameters to the
workpiece surface finish utilizing Taguchi methodology. The effects
of turning parameters were studied by using the analysis of variance (ANOVA) method. Evaluated parameters were feed, cutting speed,
and depth of cut. It was found that the most significant interaction among the considered turning parameters was between depth of cut and feed. The average surface roughness (Ra) resulted by TiN-Al2O3-
TiCN coated inserts was about 2.44 μm and minimum value was 0.74 μm. In addition, the regression model was able to predict values for surface roughness in comparison with experimental values within
reasonable limit.
Abstract: Abrasive Jet Machining is an Unconventional
machining process in which the metal is removed from brittle and
hard material in the form of micro-chips. With increase in need of
materials like ceramics, composites, in manufacturing of various
Mechanical & Electronic components, AJM has become a useful
technique for micro machining. The present study highlights the
influence of different parameters like Pressure, SOD, Time, Abrasive
grain size, nozzle diameter on the Metal removal of FRP (Fiber
Reinforced Polymer) composite by Abrasive jet machining. The
results of the Experiments conducted were analyzed and optimized
with TAGUCHI method of Optimization and ANOVA for Optimal
Value.
Abstract: Industrial surveys shows that manufacturing
companies define the qualities of thermal removing process based on
the dimension and physical appearance of the cutting material
surface. Therefore, the roughness of the surface area of the material
cut by the plasma arc cutting process and the rate of the removed
material by the manual plasma arc cutting machine was importantly
considered. Plasma arc cutter Selco Genesis 90 was used to cut
Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually
based on the selected parameters setting. The material removal rate
(MRR) was measured by determining the weight of the specimens
before and after the cutting process. The surface roughness (SR)
analysis was conducted using Mitutoyo CS-3100 to determine the
average roughness value (Ra). Taguchi method was utilized to
achieve optimum condition for both outputs studied. The
microstructure analysis in the region of the cutting surface is
performed using SEM. The results reveal that the SR values are
inversely proportional to the MRR values. The quality of the surface
roughness depends on the dross peak that occurred after the cutting
process.
Abstract: Moulded parts contribute to more than 70% of
components in products. However, common defects particularly in
plastic injection moulding exist such as: warpage, shrinkage, sink
marks, and weld lines. In this paper Taguchi experimental design
methods are applied to reduce the warpage defect of thin plate
Acrylonitrile Butadiene Styrene (ABS) and are demonstrated in two
levels; namely, orthogonal arrays of Taguchi and the Analysis of
Variance (ANOVA). Eight trials have been run in which the optimal
parameters that can minimize the warpage defect in factorial
experiment are obtained. The results obtained from ANOVA
approach analysis with respect to those derived from MINITAB
illustrate the most significant factors which may cause warpage in
injection moulding process. Moreover, ANOVA approach in
comparison with other approaches like S/N ratio is more accurate and
with the interaction of factors it is possible to achieve higher and the
better outcomes.
Abstract: Stair climbing is one of critical issues for field robots to
widen applicable areas. This paper presents optimal design on
kinematic parameters of a new robotic platform for stair climbing. The
robotic platform climbs various stairs by body flip locomotion with
caterpillar type main platform. Kinematic parameters such as platform
length, platform height, and caterpillar rotation speed are optimized to
maximize stair climbing stability. Three types of stairs are used to
simulate typical user conditions. The optimal design process is
conducted based on Taguchi methodology, and resulting parameters
with optimized objective function are presented. In near future, a
prototype is assembled for real environment testing.
Abstract: In this paper, a tooth shape optimization method for
cogging torque reduction in Permanent Magnet (PM) motors is
developed by using the Reduced Basis Technique (RBT) coupled by
Finite Element Analysis (FEA) and Design of Experiments (DOE)
methods. The primary objective of the method is to reduce the
enormous number of design variables required to define the tooth
shape. RBT is a weighted combination of several basis shapes. The
aim of the method is to find the best combination using the weights
for each tooth shape as the design variables. A multi-level design
process is developed to find suitable basis shapes or trial shapes at
each level that can be used in the reduced basis technique. Each level
is treated as a separated optimization problem until the required
objective – minimum cogging torque – is achieved. The process is
started with geometrically simple basis shapes that are defined by
their shape co-ordinates. The experimental design of Taguchi method
is used to build the approximation model and to perform
optimization. This method is demonstrated on the tooth shape
optimization of a 8-poles/12-slots PM motor.
Abstract: This study presents the numerical simulation of
optimum pin-fin heat sink with air impinging cooling by using
Taguchi method. 9 L ( 4 3 ) orthogonal array is selected as a plan for
the four design-parameters with three levels. The governing
equations are discretized by using the
control-volume-based-finite-difference method with a power-law
scheme on the non-uniform staggered grid. We solved the coupling of
the velocity and the pressure terms of momentum equations using
SIMPLEC algorithm. We employ the k −ε two-equations
turbulence model to describe the turbulent behavior. The parameters
studied include fin height H (35mm-45mm), inter-fin spacing a , b ,
and c (2 mm-6.4 mm), and Reynolds number ( Re = 10000- 25000).
The objective of this study is to examine the effects of the fin
spacings and fin height on the thermal resistance and to find the
optimum group by using the Taguchi method. We found that the fin
spacings from the center to the edge of the heat sink gradually
extended, and the longer the fin’s height the better the results. The
optimum group is 3 1 2 3 H a b c . In addition, the effects of parameters are
ranked by importance as a , H , c , and b .
Abstract: The present paper discusses the selection of process
parameters for obtaining optimal nanocrystallites size in the CuOZrO2
catalyst. There are some parameters changing the inorganic
structure which have an influence on the role of hydrolysis and
condensation reaction. A statistical design test method is
implemented in order to optimize the experimental conditions of
CuO-ZrO2 nanoparticles preparation. This method is applied for the
experiments and L16 orthogonal array standard. The crystallites size
is considered as an index. This index will be used for the analysis in
the condition where the parameters vary. The effect of pH, H2O/
precursor molar ratio (R), time and temperature of calcination,
chelating agent and alcohol volume are particularity investigated
among all other parameters. In accordance with the results of
Taguchi, it is found that temperature has the greatest impact on the
particle size. The pH and H2O/ precursor molar ratio have low
influences as compared with temperature. The alcohol volume as
well as the time has almost no effect as compared with all other
parameters. Temperature also has an influence on the morphology
and amorphous structure of zirconia. The optimal conditions are
determined by using Taguchi method. The nanocatalyst is studied by
DTA-TG, XRD, EDS, SEM and TEM. The results of this research
indicate that it is possible to vary the structure, morphology and
properties of the sol-gel by controlling the above-mentioned
parameters.
Abstract: The present work consecutively on synthesis and
characterization of composites, Al/Al alloy A 384.1 as matrix in
which the main ingredient as Al/Al-5% MgO alloy based metal
matrix composite. As practical implications the low cost processing
route for the fabrication of Al alloy A 384.1 and operational
difficulties of presently available manufacturing processes based in
liquid manipulation methods. As all new developments, complete
understanding of the influence of processing variables upon the final
quality of the product. And the composite is applied comprehensively
to the acquaintance for achieving superiority of information
concerning the specific heat measurement of a material through the
aid of thermographs. Products are evaluated concerning relative
particle size and mechanical behavior under tensile strength.
Furthermore, Taguchi technique was employed to examine the
experimental optimum results are achieved, owing to effectiveness of
this approach.
Abstract: This study has applied the L16 orthogonal array of the
Taguchi method to determine the optimized polymeric
Nanocomposite asphalt binder. Three control factors are defined as
polypropylene plastomer (PP), styrene-butadiene-styrene elastomer
(SBS) and Nanoclay. Four level of concentration contents are
introduced for prepared asphalt binder samples. all samples were
prepared with 4.5% of bitumen 60/70 content. Compressive strength
tests were carried out for defining the optimized sample via
QUALITEK-4 software. SBS with 3%, PP with 5 % and Nanoclay
with 1.5% of concentrations are defined as the optimized
Nanocomposite asphalt binders. The confirmation compressive
strength and also softening point tests showed that modification of
asphalt binders with this method, improved the compressive strength
and softening points of asphalt binders up to 55%.
Abstract: This work presents the results of a study carried out to
determine the sliding wear behavior and its effect on the process
parameters of components manufactured by direct metal laser
sintering (DMLS). A standard procedure and specimen had been used
in the present study to find the wear behavior. Using Taguchi-s
experimental technique, an orthogonal array of modified L8 had been
developed. Sliding wear testing using pin-on-disk machine was
carried out and analysis of variance (ANOVA) technique was used to
investigate the effect of process parameters and to identify the main
process parameter that influences the properties of wear behavior on
the DMLS components. It has been found that part orientation, one
of the selected process parameter had more influence on wear as
compared to other selected process parameters.
Abstract: The operating control parameters of injection
flushing type of electrical discharge machining process on stainless
steel 304 workpiece using copper tools are being optimized
according to its individual machining characteristic i.e. Electrode
Wear Ratio (EWR). Higher EWR would give bad dimensional
precision for the EDM machined workpiece because of high
electrode wear. Hence, the quality characteristic for EWR is set to
lower-the-better to achieve the optimum dimensional precision for
the machined workpiece. Taguchi method has been used for the
construction, layout and analysis of the experiment for EWR
machining characteristic. The use of Taguchi method in the
experiment saves a lot of time and cost of preparing and machining
the experiment samples. Therefore, an L18 Orthogonal array
which was the fundamental component in the statistical design of
experiments has been used to plan the experiments and Analysis of
Variance (ANOVA) is used to determine the optimum machining
parameters for this machining characteristic. The control
parameters selected for this optimization experiments are polarity,
pulse on duration, discharge current, discharge voltage, machining
depth, machining diameter and dielectric liquid pressure. The
result had shown that negative polarity machining parameter
setting will decreases EWR.
Abstract: This paper presents a comparative study of statistical methods for the multi-response surface optimization of a cryogenic freezing process. Taguchi design and analysis and steepest ascent methods based on the desirability function were conducted to ascertain the influential factors of a cryogenic freezing process and their optimal levels. The more preferable levels of the set point, exhaust fan speed, retention time and flow direction are set at -90oC, 20 Hz, 18 minutes and Counter Current, respectively. The overall desirability level is 0.7044.
Abstract: In the present study, the effects of ultrasound as
emerging technology were investigated on germination stimulation,
amount of alpha-amylase activity on dry barley seeds before steeping
stage of malting process. All experiments were carried out at 20 KHz
on the ultrasonic generator in 3 different ultrasonic intensities (20, 60
and 100% setting from total power of device) and time (5, 10 and 15
min) at constant temperature (30C). For determining the effects of
these parameters on enzyme the Fuwa method assay based on the
decreased staining value of blue starch–iodine complexes employed
for measurement an activity. The results of these assays were
analyzed by Qualitek4 software using the Taguchi statistical method
to evaluate the factor-s effects on enzyme activity. It has been found
that when malting barley is irradiated with an ultrasonic power, a
stimulating effect occurs as to the enzyme activity.
Abstract: In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.
Abstract: In this paper, the experimental design of using the
Taguchi method is employed to optimize the processing parameters in
the plasma arc surface hardening process. The processing parameters
evaluated are arc current, scanning velocity and carbon content of
steel. In addition, other significant effects such as the relation between
processing parameters are also investigated. An orthogonal array,
signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are
employed to investigate the effects of these processing parameters.
Through this study, not only the hardened depth increased and surface
roughness improved, but also the parameters that significantly affect
the hardening performance are identified. Experimental results are
provided to verify the effectiveness of this approach.