Papers by Keyword: Taguchi Method

Abstract: High productivity and product quality are sought after by manufacturers due to the increasing demand for and use of plastic items. Injection molding is the most famous method used to make majority of the plastic items. Injection molding is however known for its lengthy production durations and poor product quality. This study shows the optimization of multiple design characteristics of circular cross-sectioned conformal cooling channels in response to reducing production time while improving product quality, at the same time, using Taguchi design-of-experiments approach. Diameter, depth, and pitch were the three main design variables examined. A Computer Aided Design software was used to create three dimensional designs and to conduct simulations. The responses obtained from simulations were time for cooling to ejection temperature, overall product shrinkage, extents of warpage and dimensions of sink marks. These output parameters were taken as input variables for multi-response optimization utilizing the method of Taguchi Grey Relational evaluation. The outcome obtained revealed that the minimum design variables resulted in the concurrent minimization of all responses for the particular geometry studied. Study of variance showed that the diameter to be the design factor that most significantly influenced all the responses simultaneously. Additionally, it was shown that conformal cooling channels yield better production outcomes than straight cooling channels whereby they gave the minimum cooling time and product defects. The optimized conformal cooling channels, when compared with straight cooling channels, reduced the time to cool the product, product shrinkage, dimension of warpage, and extent of sink marks by 29.35%, 5.99%, 19.77%, and 38.85% respectively.

Abstract: Casting is one of the most commonly used manufacturing method for geometrically complex product. Among the casting technologies, sand casting is often found in application. Beside the advantages of the sand-casting process, it also has a drawback that is often encountered, namely product defects. Product defects can be caused by a lack of attention to sand casting parameters. This work aims to minimize those defects, including porosity defects, shrinkage defects and incomplete defects by optimizing process parameters using the Taguchi method. The identified sand-casting process parameters include gating location, riser location, molding conditions and pouring temperature with each parameter consisting of 3 levels. This research using the fractional factorial L₉ (3⁴). Data processing is carried out by analysis of mean (ANOM) to obtain plot effects. The results showed that the optimal combination of parameters that resulted in shrinkage, porosity and minimal incomplete defects were at gating location level 2, riser location level 1, mold condition level 2 and pouring temperature level 3. The results of the comparison before and after optimization were an increase of 0.77, where previously it was 1.30 to 2.07 based on normalized data.

Abstract: Additive Manufacturing (AM) is a technique in constructing components from a CAD model to a finished product. This is done by depositing molten material at a specific coordinate and height. This is done continuously until the finished product has been produced. Both FDM and PLA are well-known technology and material in the AM field. Optimizing the parameters will surely provide a good reach for hobbyists, researchers, and academicians. Optimization is a process concerned with the identification of the best possible value/condition for a certain parameter. Most research papers optimize a response/factor at a time given that less than five parameters are being studied. This paper aims to optimize three mechanical properties such as strength, elongation, and modulus of elasticity. This response was optimized through seven (7) benchmark parameters conducted in mixed levels (a combination of two and three levels). This paper was able to identify the optimum level per parameter, provide insight into the significant contributors affecting the target responses, and lastly, provide a contour plot to serve as a reference of AM end-users.

Abstract: The main objective of this work is to optimize welding parameters of AISI 430 FSS welds, focused to minimization of ferrite grains size using Taguchi’s design. Two input parameters of speed and welding current; were chosen to select the minimum grain size and to ascertain their effects on ferrite grain size. ANOVA method was used to evaluate the influence of varying factors on the overall quality of welds. Optimal combination of the parameters were be predicted by S/N analyses, it was accessed on employing an 80 A with 6mm/s. Experimental characterizations of optimum weld joint were performed by using tensile test assisted by image correlations, optical and electronic microscopy. As a result, welding speed had the main influence on grain size by 84.30%. Optimum welding parameter offered finest microstructure with low rate of martensite precipitates in both fusion zone and heat affected zone, and best combination of strength and ductility, it presented a homogeneous distribution of tensile stresses that caused a ductile fracture in base material. ,it is found that that optimized welding parameters permit to give greater resistance to corrosion, which exhibit a lower corrosion current, indicating that coarse ferrite grains are more susceptible to corrosion compared to fine grains.

Abstract: Fused deposition modelling (FDM) is a spectrum of techniques that enables the fabrication of objects from diverse materials, layer-by-layer, and directly from a CAD file. With the advancement of technology, the procedure has grown more adaptable and swifter. In this study, the mechanical performance and topology optimization of the polylactic acid (PLA) 3D printed hollow and thin-walled structures produced by FDM was investigated via integration of Taguchi method and Principal Component Analysis (PCA). Eleven factors namely topology design (square), wall thickness (1 mm), layer height (0.3 mm), infill density (20%), infill layer thickness (0.6 mm), infill flow (80%), infill pattern (Octet), print speed (80 mm/s), printing temperature (210°C), bed temperature (65°C), and orientation direction (flat along the y-axis) were identified as the optimal factors for the 3D printed part. The integration approach concurrently solves the problem in particular for numerous quality criteria, especially in 3D printing. Integrating the Taguchi method with PCA can help to improve the quality of the final product or process, and enhance the understanding of the underlying relationships between variables.

Abstract: In this study, the L934 orthogonal table of the Taguchi method is used as a systematic parameter analysis. A rapid prototyping machine (RPM, manufactured by the research team) and fused deposition modeling (FDM) are used to make anti-vibration test specimens and to analyze the effect of different process parameters, such as weaving and shaping, on vibration resistance. Hopefully, various application fields will be extended via the deposition method. The impact test is executed by dropping a steel ball onto each test piece which is connected to an accelerometer and a PW700 spectrometer for extracting the frequency response during the impact. The vibration performance under different process parameters is analyzed. Several parameters that may affect anti-vibration performance are selected under the existing process, namely weaving method (A), deposition thickness (B), weaving density (C) and cross weaving per n-layer (D). The policy is to evaluate the required time period to restore to the steady state after impact. Hence, the shorter the convergence time is, the better the specimen resists the vibration. The experimental results show that the build-up layer thickness and the weaving density are the main control factors that affect the anti-vibration ability most. The process parameter A3B1C1D2 obtains the best vibration resistance performance.

Abstract: Utilizing local materials and recycling waste has the potential to yield both ecological and economic advantages in the field of construction materials. In this context, the object of this work is to apply Taguchi's design of experiments on cement eco-mortar, which were designed using an L-9 orthogonal array, to optimize and model the effect of dune sand of the El Oued region, rubber aggregates, and crushed clay brick waste on the mechanical strength at 28 days. The different interactions were also investigated between the factors targeted in our study, namely: dune sand (DS) content, rubber aggregates (RA) content, and brick waste (BW) content. The results of the analysis of variation (ANOVA) as well as the mathematical models developed in this study showed that the BW factor content has a positive effect on compressive strength and a negative effect on flexural strength. In addition, the interactions between DS and BW contents and between RA and BW contents have a negative effect on the compressive strength of eco-mortar. With regard to flexural strength, the results showed that the interaction between the factors DS and RA contents has a negative effect on flexural strength, in contrast to the interaction between the RA and BW contents, which has a positive effect.

Abstract: In this work, an attempt is made to reduce Molding defects using Taguchi Method. The input parameters used are Runner Lower Diameter, Runner Upper Diameter, Runner height, In gate height, and Pouring time. The response parameters selected as per the study of molding process requirements of the industry are Product yield(%). The L8 orthogonal array is used as per Taguchi method. The experimentation is conducted and the responses are measured. Significant progress has been made in determining the appropriate values of molding process variables to expand molding quality using diverse techniques during the last few decades. The design of sand-molding process variables has been recognized as one of the most critical aspects of molding quality. This research work focuses on improving the molding quality and yield percentage. The data analysis is made by S/N ratio and ANOVA. The result revealed the optimal setting to minimize the defect.

Abstract: Here performance evaluation of Self Compacting Alkali Activated Slag Concrete incorporating Reclaimed Asphalt Pavement as fine aggregate was carried out. Investigation on mechanical properties by replacing the fine aggregate by Reclaimed Asphalt Pavement in different proportions were also evaluated. Development of Self Compacting Alkali Activated Concrete mixes (SCAAC) was made with GGBFS and Lime are used binders, with binder content varying between 550 to 650 kg/m³ of fresh concrete and lime content varying from 10% to 20% of binder content. The net W/B ratio of the mixes was kept around 0.57. The fine aggregate was replaced by Reclaimed Asphalt Pavement with percentage replacement from 50 to 100% of Crushed Stone Sand. The alkaline solutions had Na₂O dosage percentages in the range 5-6% with a constant activator modulus maintained at 1. By using Minitab Statistical Software nine mixes were produced with 4 factors and 3 levels. In this study the TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution) optimization technique was carried out to know the effectiveness. Results showed the slump flow greater than 650 mm, with their L–Box, U-box and V-Funnel values ranging between 0.85,20mm and10s respectively, results showed enhanced mechanical properties as compared to control OPCC mix.

Abstract: The present work describes a heat treatment procedure using nanofluids as quenchants for (AISI 52100 Steel) via the Taguchi method to optimize process parameters. The nanofluids have been prepared from nanoparticles (SiO₂, SiC and Fe₂O₃) and base media consist of distilled water, toluene and ethylene glycol of volume concentrations of 0.02, 0.04 and 0.06 %. The present investigation considers hardness and wear rate as optimization criteria. The experimental variables that were selected for this study are: (austenitizing and tempering temperature), (type and volume fraction of nanoparticles) and (base media). They represent significant factors that influence on these optimization criteria. (AL18 orthogonal array), (analysis of variances (ANOVA)) and (signal/noise ratio (S/N)) were applied by means of (Minitab 18) software to examine the performance characteristics of the process parameters. The analysis of (S/N) ratio shows that the most significant parameters that give the optimum heat treatment conditions for hardness of the examined steel (AISI 52100) are: (austenitizing temperature of 800°C), (distilled water as a type of base media) and (tempering temperature of 180°C), in addition to (Fe₂O₃ as a nanoparticles type) and finally (nanoparticles volume fraction of 0.06%). In contrast, for the wear rate, they were: (austenitizing temperature of 800°C), type of base media (distilled water), tempering temperature of (180°C), and volume fraction of nanoparticles (0.06%) tempering. Finally, nanoparticles type (Fe₂O₃) is the most significant parameter for hardness and wear rate. ANOVA, exhibited that the austenitizing temperature has major effect on producing high values of hardness and wear rate for the AISI 52100 Steel.