Abstract: Response Surface Methods (RSM) provide
statistically validated predictive models that can then be manipulated
for finding optimal process configurations. Variation transmitted to
responses from poorly controlled process factors can be accounted
for by the mathematical technique of propagation of error (POE),
which facilitates ‘finding the flats’ on the surfaces generated by
RSM. The dual response approach to RSM captures the standard
deviation of the output as well as the average. It accounts for
unknown sources of variation. Dual response plus propagation of
error (POE) provides a more useful model of overall response
variation. In our case, we implemented this technique in predicting
compressive strength of concrete of 28 days in age. Since 28 days is
quite time consuming, while it is important to ensure the quality
control process. This paper investigates the potential of using design
of experiments (DOE-RSM) to predict the compressive strength of
concrete at 28th day. Data used for this study was carried out from
experiment schemes at university of Benghazi, civil engineering
department. A total of 114 sets of data were implemented. ACI mix
design method was utilized for the mix design. No admixtures were
used, only the main concrete mix constituents such as cement, coarseaggregate,
fine aggregate and water were utilized in all mixes.
Different mix proportions of the ingredients and different water
cement ratio were used. The proposed mathematical models are
capable of predicting the required concrete compressive strength of
concrete from early ages.
Abstract: 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.
Abstract: The primary objective of this work was to study the
effect of resin chemistry, pH and molarity of binding and elution
buffer on aggregate removal using Cation Exchange Chromatography
and find the optimum conditions which can give efficient aggregate
removal with minimum loss of yield. Four different resins were used
for carrying out the experiments: Fractogel EMD SO3
-(S), Fractogel EMD COO-(M), Capto SP ImpRes and S Ceramic HyperD. Runs
were carried out on the AKTA Avant system. Design of Experiments
(DOE) was used for analysis using the JMP software. The
dependence of the yield obtained using different resins on the
operating conditions was studied. Success has been achieved in
obtaining yield greater than 90% using Capto SP ImpRes and
Fractogel EMD COO-(M) resins. It has also been found that a change
in the operating conditions generally has different effects on the
yields obtained using different resins.
Abstract: The use of titanium fluoride and iron fluoride
(TiF3/FeF3) catalysts in combination with polutetrafluoroethylene
(PTFE) in plain zinc- dialkyldithiophosphate (ZDDP) oil is important
for the study of engine tribocomponents and is increasingly a strategy
to improve the formation of tribofilm and provide low friction and
excellent wear protection in reduced phosphorus plain ZDDP oil. The
influence of surface roughness and the concentration of
TiF3/FeF3/PTFE were investigated using bearing steel samples
dipped in lubricant solution at 100°C for two different heating time
durations. This paper addresses the effects of water drop contact
angle using different surface; finishes after treating them with
different lubricant combination. The calculated water drop contact
angles were analyzed using Design of Experiment software (DOE)
and it was determined that a 0.05 μm Ra surface roughness would
provide an excellent TiF3/FeF3/PTFE coating for antiwear resistance
as reflected in the Scanning electron microscopy (SEM) images and
the tribological testing under extreme pressure conditions. Both
friction and wear performance depend greatly on the PTFE/and
catalysts in plain ZDDP oil with 0.05 % phosphorous and on the
surface finish of bearing steel. The friction and wear reducing effects,
which was observed in the tribological tests, indicated a better micro
lubrication effect of the 0.05 μm Ra surface roughness treated at
100°C for 24 hours when compared to the 0.1 μm Ra surface
roughness with the same treatment.
Abstract: The reduction of phosphorus and sulfur in engine oil
are the main topics of this paper. Very reproducible boundary
lubrication tests were conducted as part of Design of Experiment
software (DOE) to study the behavior of fluorinated catalyst iron
fluoride (FeF3), and polutetrafluoroethylene or Teflon (PTFE) in
developing environmentally friendly (reduced P and S) anti-wear
additives for future engine oil formulations. Multi-component
Chevron fully formulated oil (GF3) and Chevron plain oil were used
with the addition of PTFE and catalyst to characterize and analyze
their performance. Lower phosphorus blends were the goal of the
model solution. Experiments indicated that new sub-micron FeF3
catalyst played an important role in preventing breakdown of the
tribofilm.
Abstract: 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.
Abstract: Submerged arc welding is a very complex process. It
is a very efficient and high performance welding process. In this
present study an attempt have been done to reduce the welding
distortion by increased amount of oxide flux through TiO2 in
submerged arc welding process. Care has been taken to avoid the
excessiveness of the adding agent for attainment of significant
results. Data Envelopment Analysis (DEA) based BAT algorithm is
used for the parametric optimization purpose in which DEA is used
to convert multi response parameters into a single response
parameter. The present study also helps to know the effectiveness of
the addition of TiO2 in active flux during submerged arc welding
process.
Abstract: There is not much effective guideline on development of design parameters selection on spring back for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for spring back in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in Uchannel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24 ). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on spring back of flange angle (β2 ) and wall opening angle (β1 ), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the spring back behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for spring back was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values.
Abstract: The present study was undertaken to investigate the
effect of aging parameters (time and temperature) on the mechanical
properties of Be-and/or Zr- treated Al-Mg-Zn (7075) alloys. Ultimate
tensile strength, 0.5% offset yield strength and % elongation
measurements were carried out on specimens prepared from cast and
heat treated 7075 alloys containing Be and/or Zr. Different aging
treatment were carried out for the as solution treated (SHT)
specimens (after quenching in warm water). The specimens were
aged at different conditions; Natural and artificial aging was carried
out at room temperature, 120C, 150C, 180C and 220C for different
periods of time. Duplex aging was performed for SHT conditions
(pre-aged at different time and temperature followed by high
temperature aging). Ultimate tensile strength, yield strength and %
elongation data results as a function of different aging parameters are
analysed. A statistical design of experiments (DOE) approach using
fractional factorial design is applied to acquire an understanding of
the effects of these variables and their interactions on the mechanical
properties of Be- and/or Zr- treated 7075 alloys. Mathematical
models are developed to relate the alloy mechanical properties with
the different aging parameters.
Abstract: Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
Abstract: 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.
Abstract: In this study, Electrical Discharge Machining (EDM) is used to modify the surface of high carbon steel En31 with the help of tool electrode (Copper-Chromium-Nickel) manufactured by powder metallurgy (PM) process. The effect of EDM on surface roughness during surface alloying is studied. Taguchi’s Design of experiment (DOE) and L18 orthogonal array is used to find the best level of input parameters in order to achieve high surface finish. Six input parameters are considered and their percentage contribution towards surface roughness is investigated by analysis of variances (ANOVA). Experimental results show that an hard alloyed surface (1.21% carbon, 2.14% chromium and 1.38% nickel) with surface roughness of 3.19µm can be generated using EDM with PM tool. Additionally, techniques like Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) are used to analyze the machined surface and EDMed layer composition, respectively. The increase in machined surface micro-hardness (101%) may be related to the formation of carbides containing chromium.
Abstract: 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.
Abstract: The quality of video transmitted by mobile ad hoc networks (MANETs) can be influenced by several factors, including protocol layers; parameter settings of each protocol. In this paper, we are concerned with understanding the functional relationship between these influential factors and objective video quality in MANETs. We illustrate a systematic statistical design of experiments (DOE) strategy can be used to analyze MANET parameters and performance. Using a 2k factorial design, we quantify the main and interactive effects of 7 factors on a response metric (i.e., mean opinion score (MOS) calculated by PSNR with Evalvid package) we then develop a first-order linear regression model between the influential factors and the performance metric.
Abstract: This paper deals with the conceptual design of Experimental Helium Cooling Loop (EHCL) for Indian Test Blanket Module (TBM) and its related thermal hydraulic experiments. Indian TBM team is developing Lead Lithium cooled Ceramic Breeder (IN-LLCB) TBM to be tested in ITER. The TBM box structure is cooled by high pressure (8 MPa) and high temperature (300-500C) helium gas.
The first wall of TBM made of complex channel geometry having several parallel channels carrying helium gas for efficient heat extraction. Several mock-ups of these channels need to be tested before finalizing the TBM first wall design and fabrication. Besides the individual testing of such mock-ups of breeding blanket, the testing of Pb-Li to helium heat exchanger, the operational experience of helium loop and understanding of the behavior of high pressure and high temperature system components are very essential for final development of Helium Cooling System for LLCB TBM in ITER. The main requirements and characteristics of the EHCL and its conceptual design are presented in this paper.
Abstract: Finned-tube heat exchangers are predominantly used in space conditioning systems, as well as other applications requiring heat exchange between two fluids. The design of finned-tube heat exchangers requires the selection of over a dozen design parameters by the designer such as tube pitch, tube diameter, tube thickness, etc… Finned-tube heat exchangers are common devices; however, their performance characteristics are complicated. In this paper numerical studies have been carried out to analyze the performances of finned tube heat exchanger (without fins considered for experimental purpose) by predicting the characteristics of temperature difference and pressure drop. In this study, a design considering 5 design variables and also maximizing the temperature difference and pressure drop was suggested by applying DOE. During this process, L18 orthogonal array was adopted. Parametric analytical studies have been carried out using ANOVA to determine the relative importance of each variable with respect to the temperature difference and the pressure drop. Following the results, the final design was suggested by predicting the optimum design therefore confirming the optimized condition.
Abstract: Artificial neural networks (ANN) are used in distinct researching fields and professions, and are prepared by cooperation of scientists in different fields such as computer engineering, electronic, structure, biology and so many different branches of science. Many models are built correlating the parameters and the outputs in electrical discharge machining (EDM) concern for different types of materials. Up till now model for Ti-5Al-2.5Sn alloy in the case of electrical discharge machining performance characteristics has not been developed. Therefore, in the present work, it is attempted to generate a model of material removal rate (MRR) for Ti-5Al-2.5Sn material by means of Artificial Neural Network. The experimentation is performed according to the design of experiment (DOE) of response surface methodology (RSM). To generate the DOE four parameters such as peak current, pulse on time, pulse off time and servo voltage and one output as MRR are considered. Ti-5Al-2.5Sn alloy is machined with positive polarity of copper electrode. Finally the developed model is tested with confirmation test. The confirmation test yields an error as within the agreeable limit. To investigate the effect of the parameters on performance sensitivity analysis is also carried out which reveals that the peak current having more effect on EDM performance.
Abstract: Glass fiber reinforced polymer (GFRP) laminates have been widely used because of their unique mechanical and physical properties such as high specific strength, stiffness and corrosive resistance. Accordingly, the demand for precise grinding of composites has been increasing enormously. Grinding is the one of the obligatory methods for fabricating products with composite materials and it is usually the final operation in the assembly of structural laminates. In this experimental study, an attempt has been made to develop an empirical model to predict the surface roughness of ground GFRP composite laminate with respect to the influencing grinding parameters by factorial design approach of design of experiments (DOE). The significance of grinding parameters and their three factor interaction effects on grinding of GFRP composite have been analyzed in detail. An empirical equation has been developed to attain minimum surface roughness in GFRP laminate grinding.
Abstract: In the present study, effect of critical medium components (a total of fifteen components) on ethanol production from waste cashew apple juice (CAJ) using yeast Saccharomyces diasticus was studied. A statistical response surface methodology
(RSM) based Plackett-Burman Design (PBD) was used for the design of experiments. The design contains a total of 32 experimental trails. The effect of medium components on ethanol was studied at two different levels such as low concentration level (-) and high concentration levels (+). The dependent variables selected in this study were ethanol concentration (g/L) and cellmass concentration (g/L). Data obtained from RSM on ethanol production were subjected to analysis of variance (ANOVA). In general, initial substrate concentration significantly influenced the microbial growth and product formation. Of the medium components evaluated, CAJ concentration, yeast extract, (NH4)2SO4, and malt extract showed significant effect on ethanol fermentation. A second-order polynomial model was used to predict the experimental data and the model fitted the data with a high correlation coefficient (R2 > 0.98).
Maximum ethanol (15.3 g/L) and biomass (6.4 g/L) concentrations
were obtained at the optimum medium composition and at optimum
condition (temperature-30°C; initial pH-6.8) after 72 h fermentation
using S.diasticus.
Abstract: The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.
Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.
Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.
This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HRC=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,
Ra= 0.305-0.005X1 - 0.0175X2 + 0.0525X4 + 0.0125X1X4 -0.02X2X4 - 0.0375X3X4
Hv=160.625 -2.37 5X1 + 5.125X2 + 1.875X3 + 4.375X4 - 1.625X1X4 + 4.375X2X4 - 2.375X3X4
High surface microhardness (175HV) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.