Box-Behnken Design Approach Research Articles

Optimization of Acid Activated Ngbo Clay Catalysts in Esterification Reaction Using Response Surface Methodology

In this study, Box-Behnken”s Response Surface Methodology (RSM) was applied to study the esterification reaction effectiveness of acid activated Ngbo clay catalyst. The esterification were monitored based on the process conditions of temperature, duration, amount of reactant, catalyst weight and particle size. The Box--Behnken’s Response Surface Methodology indicates that the acid clay-catalysed esterification reactions proceed through dual mechanisms of Acid-complex and Alcohol-complex mechanisms with the Alcohol mechanism dominating. The esterification efficiencies of acetic acid and ethanol by acid activated Ngbo clay catalyst optimized using RSM models indicated the estimated esterification percentage of ˃99%. The predicted and experimental values under the same conditions showed less than 5% difference thereby making the Box-Behnken design approach an efficient, effective and reliable method for the esterification of acetic acid with ethanol. The produced catalyst was optimized using A-One way ANOVA modelling, which indicated correlation coefficient of the regression of 0.9940, which implies that 99.40% of the total variation in the esterification reaction was attributed to the experimental variables. The result obtained indicated that the process could be applied in the esterification of acetic acid to avoid the drawbacks of corrosion, loss of catalyst and environmental problems.

Wear characteristics of additively manufactured AlSi10Mg against EN-31 and silicon carbide abrasive sheet counter bodies using box Behnken design approach

High strength-to-weight ratio materials are used in the automotive and aerospace industries, and AlSi10Mg is suitable for those applications. The research aims to compare and investigate the wear characteristics of selective laser melted AlSi10Mg pin against two counter bodies, EN-31 hardened steel, and silicon carbide abrasive sheet. The wear rate of additively manufactured AlSi10Mg pin at 0° building orientation was investigated using the box Behnken design approach to identify the suitable wear parameters with the pin on the disc testing facility. Based on analysis of variance, the interaction of load with sliding distance significantly influenced the wear rate of AlSi10Mg in both counter body cases. The adhesion and abrasion wear mechanism were observed in AlSi10Mg with EN-31 and silicon carbide abrasive sheet, respectively. The findings reveal the effect of two counter bodies on the SLMed AlSi10Mg wear phenomenon. Finally, severe wear was observed in the AlSi10Mg pin against the silicon carbide counter body.

Chlorella sorokiniana cultivation in cheese whey for β-galactosidase production

Biotechnological processes with microalgae with the aim to achieve high biomass yields must choose the appropriate nutrients and physicochemical parameters, taking into account the specific characteristics of each species to determine the basic needs for its growth. In the present study, the better growth condition of Chlorella sorokiniana IPR 7104 was optimized to reach the maximum beta-galactosidase production. The cheese whey concentration (%), temperature (˚C) and pH were factors investigated and a Box-Behnken Design (BBD) approach was implemented using Statistica 7.0 software. We observed that the cultivation condition to Chlorella sorokiniana IPR 7104 was the heterotrophic, which showed the major enzymatic activity, consequently a lower residual lactose content. Under heterotrophic conditions (without light) the β-galactosidase activity increased linearly until the 8th day. Biomass production grew linearly on the 12th day. The microalgae consumed 89.6% of lactose in 3 days, showing a high capacity to metabolize this disaccharide, through β-galactosidase synthesis. The maximum β-galactosidase production by Chlorella sorokiniana IPR 7104, in heterotrophic conditions and using cheese whey as carbon source, is obtained using the following conditions: 30°C temperature, concentration of ethanol at 20% and time of 4 min.

Decolourisation of textile dye by laccase: Process evaluation and assessment of its degradation bioproducts

Biodegradation of environmentally hazardous synthetic dyes by enzymes has been achieved the highest interest in recent years. In this work, we optimized Remazol Brilliant Blue R (RBBR) dye biodegradation by Arthrographis kalrae derived laccase via the Box-Behnken design (BBD) approach of the surface response methodology (RSM). Optimization of dye decolourisation by one variable at a time (OVAT) approach resulted in optimal dye decolourisation at laccase dose (2 IU mL−1), pH (7.0), temperature (35 °C), incubation time (240 min), and initial dye concentration (100 mg L-1). The optimized process through BBD enhanced dye decolourisation (97.18%). Fourier Transform Infrared Spectroscopy and UV–Visible Spectrophotometry have proven biodegradation. In addition, in comparison to untreated samples, the laccase-treated dye sample showed relatively less phyto- and cytotoxic effect on Allium cepa L. Extra Precision Glide docking exhibited the binding affinity score of −5.355 kcal mol−1, between laccase-RBBR complex.

Optimising the Workability and Strength of Concrete Modified with Anacardium Occidentale Nutshell Ash

Strength failure persists both in structural and mechanical analysis. One of its prominent characteristics is the adequate provision for parameters that minimise or maximise strength objectives while satisfying boundary conditions. The previous optimisation of concrete strength usually neglects mix design mechanisms induced by optimisation. Recent efforts to accurately optimise the concrete compressive strength have factored in some of these mechanisms. However, optimising concrete strength modified with high silica and alumina precursors, and crucial mix design factors are rare. Consequently, this paper optimised the concrete workability and strength, incorporating binding, water/binder ratio, binder/aggregate ratio, and curing mechanisms using the Box–Behnken design approach (BBDA). A waste material, anacardium occidentale (cashew) nutshell ash, was valorised and used at 5, 10, and 15 wt.% of cement. The composites were made, cured and tested at 14–90 d. The results revealed a high precision between the experimental slump and the optimisation slump at 97% R2. In addition, a 5% increase in compressive strength was obtained compared with the target compressive strength. Besides, the correlation between the model equation obtained from this study and predictions of previous studies via BBDA yielded a strong relationship.

Simultaneous improvement of microgeometry and surface quality of spur and straight bevel gears by abrasive flow finishing process

This article reports on influence of extrusion pressure, abrasive particle size and volumetric concentration on simultaneous reduction of surface roughness and microgeometry errors of spur and straight bevel gear by abrasive flow finishing (AFF) process. A vertical configured experimental apparatus was developed for two-way AFF and developed fixtures for finishing gears. Experimental investigations were conducted to identify optimum parametric combination, using response surface methodology, based on Box–Behnken design approach. Results revealed that higher values of abrasive particle size and volumetric concentration yield more percentage decrease in surface roughness and microgeometry error. Roughness profile, bearing area curve, microhardness, surface morphology, and wear resistance of the gear having best quality finishing were studied. Surface morphology analysis of the flank regions of the best finished spur and straight bevel gears found them to be smooth and free from cracks and burrs. Reciprocating wear test results revealed higher wear resistance of the AFF finished gears as compared to the unfinished gears. AFF also enhanced microhardness of the finished gears, which would enhance their operating performance and service life. This study shows that AFF is a flexible, economical, productive, easy to operate, and sustainable nontraditional process for precision finishing of gear that can simultaneously improve microgeometry, surface finish, microhardness, surface morphology, wear resistance, and residual stresses of the finished gears. Gear manufacturers and users will be benefited by the outcome of this study. JEL codes: C00, C20

Heat-treated gilsonite as an efficient natural material for removing toluene: A Box-Behnken experimental design approach

Heat-treated Gilsonite (HT-Gil) has been used for the adsorptive removal of toluene from wastewater. Characterization of the sample was carried out by utilizing appropriate standard test methods. The FT-IR spectrum indicates the presence of long aliphatic chains and aromatic rings. FE-SEM imaging is employed for investigating the surface morphology, the grain size of the sample and confirms the irregular shape of the HT-Gil with different particle size distributions. Determination of chemical properties and elemental composition of the sample was conducted according to several ASTM tests along with XRF analysis. Also, TGA experimental results revealed the thermal stability of the sample up to 350 °C. Optimization of adsorption parameters, including temperature (A: 5-45 °C), pH (B: 4-9), and contact time (C: 20-90 min) was performed by BBD. The results showed that the maximum adsorption capacity of 69.1% was achieved in the optimum condition containing 5 °C, pH 9, and 90 min. The spent adsorbent also has acceptable adsorption efficiency (62.12%) after four thermal regeneration cycles. Moreover, the results of equilibrium data were in accordance with the Freundlich isotherm model (R2 = 0.9531) and imply the non-uniformity of the adsorbent surface that is in line with those found previously in the literature.

Development of an HPLC-MS method for the determination of four terpene trilactones in Ginkgo biloba leaf extract via quality by design.

Previously reported HPLC-evaporative light scattering detection methods for terpene trilactone determination in Ginkgo biloba leaf extract (EGBL) have complicated sample preparation steps and are time-consuming. Thus, in this work, an HPLC-MS method for the determination of terpene trilactones in EGBL was developed with a novel analytical quality by design approach to provide robust and simple measurements. For this purpose, analytical target profiles and systematic risk analyses were performed to identify potential critical method attributes and critical method parameters. After screening experiments, a Box-Behnken design approach was utilized to investigate the relationships between critical method attributes and critical method parameters. A hypercube design space obtained by a Monte Carlo method was used for choosing the analytical control strategy. Then, verification experiments were performed within the design space, and the models were found to be accurate. After that, the optimized method was verified and successfully used for quality control analysis of EGBL from different manufacturers, and the results were almost the same as those determined by HPLC-evaporative light scattering detection. To our knowledge, this is the first study to establish a robust HPLC-MS method for determination of terpene trilactones in EGBL based on a novel analytical quality by design concept, which can improve the quality control of commercial EGBL.

Semi-empirical modeling and optimization of process parameters on overcut during MFAPM-EDM of Al6061 alloy

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) process is a hybrid process machining process which improves the machining characteristics and stability of process using assistive magnetic field and dielectric admixed powder. In this article, study on overcut has been performed on MFAPM-EDM machined Aluminium 6061 alloy. Discharge current, powder concentration, pulse on duration, pulse off duration, and magnetic field strength as process parameters have been varied during experimentation. Box Behnken design approach was employed for experimental design to carry out the experiments. Suitable Semi-empirical model was formulated using dimensional analysis for predicting the overcut. The empirical model developed was also compared with RSM model and was found better in predicting the response. Optimum process parameters for minimal overcut was conducted desirability function approach of RSM. Experimental results divulged discharge current as the most important parameters for overcut as compared to other process parameters on account of higher F-value. Confirmatory experiments revealed good correlation between optimum and experimental results.

Experimental analysis on density, micro-hardness, surface roughness and processing time of Acrylonitrile Butadiene Styrene (ABS) through Fused Deposition Modeling (FDM) using Box Behnken Design (BBD)

Fused Deposition Modeling (FDM), recently denoted by Fused Filament Fabrication (FFF), is a promising polymer processing method commonly used in the additive manufacturing domain for achieving closed dimensional tolerance. Moreover, processing on Acrylonitrile Butadiene Styrene (ABS) by FDM results in precision components manufacturing for several industrial applications. Here, an experimental attempt was conducted to find the individual and interaction effects of FDM input process parameters on ABS polymer parts. Experiments are designed based on Box Behnken Design (BBD) approach. A set of 15 experiments were carried out with varying input parameters of infill percentage (%), layer height (μm) and bed temperature (°C). These input parameters of FDM shows much influence on density, processing time/printing time, surface roughness and micro-hardness of ABS coupons/samples. It was observed that the above outputs are significantly influenced by the individual and the interaction effects of process parameters. Finally, the validation study was performed to verify the regression equation for all responses.

Effect of Friction Stir Process Parameters on Mechanical Properties of Al/Eggshell/SiC Composite Material

The rise in pollution is a serious matter of concern for all nations. Industries are mainly responsible for damaging the balance of the cycle of pollution. In this paper, the mechanical properties of Aluminum have been enhanced by reinforcing it with eggshell wastes and SiC as reinforcement particles. Ball-milling technique has been applied for up to 75 hours for making the densities of Aluminum, Eggshell and SiC equal. The prime focus of this work is to improve the hardness value of Aluminium-based final composite material. Friction Stir Process (FSP) technique has been used to develop the composite and the driving parameters of FSP like rotational speed, transverse speed etc. are optimized with the help of the Box-Behnken Design approach. The optimized value of rotation speed was 966.14 rpm as well as transverse speed was 23.18 mm/min. Hardness and tensile strength of composite developed at an optimum combination of parameters were found to be 72.2 BHN and 194.48 MPa respectively. Results showed that tensile strength and hardness were enhanced by about 44.05% and 64.09% respectively.

Optimization of laser melting parameter to enhanced surface properties in hot press forming die

This paper presents laser melting process with various parameter to enhanced surface properties of AISI H13 tool steel. The design of experiment (DOE) optimisation was conducted to obtain significant model using regression analysis. DOE were analysed using response surface method (RSM) with Box-Behnken design approach. Design Expert 7 software was used to design parameter of laser melting process. The laser melting processes was conducted using Nd:YAG laser system with pulsed mode at a constant average power of 100 W, overlapping rate of 30 to 50%, peak power of 1700 to 2500 W and pulse repetition frequency (PRF) of 50 to 70 Hz respectively. The responses were characterised for sub-surface hardness, melt depth and surface roughness. The results show that optimum parameter of 2500 W peak power, 60 Hz PRF and 30% overlapping rate produced highest surface hardness of 793.7 HV0.1 with 0.21 mm melted depth and 3.89 µm surface roughness from experimental data. This finding was important to enhance properties of AISI H13 tool steel for hot press forming die using laser process.

A potential type-II L-asparaginase from marine isolate Bacillus australimaris NJB19: Statistical optimization, in silico analysis and structural modeling

L-asparaginase is a cardinal biotherapeutic drug for treating acute lymphoblastic leukemia, which is highly prevalent in children worldwide. In the current investigation, L-asparaginase producing marine bacterial isolate, Bacillus australimaris NJB19 (MG734654), was observed to be producing extracellular glutaminase free L-asparaginase (13.27 ± 0.4 IU mL−1). Production of L-asparaginase was enhanced by the Box-Behnken design approach that enumerated the significant variables affecting the enzyme production. The optimum levels of the derived variables resulted in 2.8-fold higher levels of the enzyme production (37.93 ± 1.06 IU mL−1). An 1146 bp L-asparaginase biosynthetic gene of Bacillus australimaris NJB19 was identified and cloned in E. coli DH5α, fused with a histidine tag. The in silico analysis of the protein sequence revealed the presence of a signal peptide and classified it as a type II L-asparaginase. Toxic peptide prediction disclosed no toxin domain in the protein sequence, hence suggesting it as a non-toxic protein. The secondary structure analysis of the enzyme displayed a comparable percentage of alpha-helical and random coil structure, while 14.39% and 6.57% of amino acid residues were composed of extended strands and beta-turns, respectively. The functional sites in the three-dimensional structural model of the protein were predicted and interestingly had a few less conserved residues. Bacillus australimaris NJB19 identified in this study produces type-II L-asparaginase, known for its high affinity for asparagine and effectiveness against leukemic cells. Hence, these observations indicate the L-asparaginase, thus obtained, as a potentially significant and novel therapeutic drug.

Modeling and Optimization of Electric Discharge Machining Process Parameters in machining of Al 6061/SiCp Metal Matrix Composite

Abstract The present work deals with EDM machining of Aluminium metal matrix composite (MMC) Al 6061 reinforced with 8% wt SiC particle which was fabricated in house by stir casting process. Fabricated MMC was machined by ZNC Electric Discharge Machining (EDM). Response surface methodology (RSM) was used for mathematical modelling and optimization of process parameters such as peak current, pulse on time and duty cycle. Box-Behnken Design (BBD) approach was used to create experimental design. Mathematical model was developed between selected input process parameters and responses such as Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (SR). Analysis of variance (ANOVA) was carried out to find significance of process parameters. The theory of desirability was used for choosing the optimal combination of process parameter.

Box-Behnken Design Approach for Optimization of a Liquid Chromatographic Method for the Determination of Anti Leukemic Drugs in Bulk and Pharmaceutical Formulations

To develop and validate a RP-HPLC method for the determination of selected anti- leukemic drugs in bulk and pharmaceutical formulations using Design of experiments. Development of the chromatographic method is based on design of experiments (DOE) approach, utilizing two level full factorial design for screening and Box-Behnken experimental design for optimization. In order to identify the significant parameters for the optimization, by simultaneously registering the main, interaction and quadratic effects of three factors such as volume of methanol (X1), concentration of buffer(X2) and flow rate (X3) on the selected responses like capacity factor K1 of first eluted peak (Y1), resolution of critical peaks RS (1,2) (Y2) and amp; RS (2,3) (Y3) and retention time of last peak tR4 (Y4) as responses. Analytes were separated on a Onyx monolithic- C18 (100×4.6mm) with mobile phase comprising Potassium dihydrogen orthophosphate (0.01M), Methanol and Acetonitrile in ratio of (30:34.29:35.71), with flow rate of 0.723 mL/min and pH 3.5 adjusted with dilute orthophosphoric acid. Total chromatographic analysis time per samples was approximately 5 minutes with DST(IS), IMT, IBT and SFN eluting with retention times of 2.64, 3.05, 3.81 and 4.59 minutes respectively. Calibration curves were linear over selected range 0.997 for the all analytes. The method was sensitive with the LODs were 10.457, 13.07 and 26.169 ng/mL and LOQs were 31.68, 39.6 and 79.3ng/mL for IMT, IBT and SFN respectively. Inter and Intra-day precision data (in terms of %RSD) was fond to be less than ≥3 respectively, Recoveries ranged ≥102±2% for Imatinib- Gleevec, Ibrutinib- Imbruvica and Sorafenib- Nexavar. The obtained results corroborated the potential of the proposed method for determination of all the three anti-leukemic drugs for routine analysis for products of similar type and composition.

Effect of friction stir process parameters on tensile strength of eggshell and SiC-reinforced aluminium-based composite

PurposeThis study aims to minimize pollution and enhance the mechanical properties of SiC- reinforced aluminum- based composite by utilizing waste eggshell. Pollution is increasing at an exponential rate across the globe. Every nation is struggling to have strong control over the rise in pollution. Many countries are even successful in this regard, but only up to a certain extent; also, a lot of capital investment is required just to make arrangements for making and taking care of dedicated dump yards. An alternative approach in this regard could be using the unwanted wastes in some constructive works by recycling them. Novel strategies and dedicated cells for the research and development regarding the recycling of various kinds of wastes are continuously being developed by various nations.Design/methodology/approachThis study attempts to make a hybrid composite of AA6101 alloy through the friction stir process (FSP) technique in which waste eggshells and SiC have been used as reinforcement particles. As the densities of eggshells, SiC show different values of densities to make them a single entity, they were subjected to ball milling for around 75 h. After ball milling, the reinforcement particles (eggshells and SiC) were distributed uniformly in the metal matrix (Al), and they appear as a single entity in the metal matrix composite.FindingsThe main objective of this study is to obtain an enhanced value of tensile strength of the final composite. Concerning this, the parameters of FSP, i.e. rotational speed and transverse speed, have been optimized through the Box–Behnken design approach. The optimized values of FSP parameters came out to be as 935.92 rpm of rotational speed and 22.48 mm/min as transverse speed value.Originality/valueThe results showed that the tensile strength and hardness of the composite developed at an optimum combination of FSP parameters enhanced by about 47.14 and 45.45%, respectively.

Experimental Investigation on Recast Layer and Surface Roughness on Aluminum 6061 Alloy During Magnetic Field Assisted Powder Mixed Electrical Discharge Machining

Surface integrity aspects have been recognized as key research areas for manufacturing industries for determining the quality, longevity and reliability of machined engineering components. Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is technological advancement in EDM process where the performance and stability of process increases by adding the suitable conductive powder in dielectric and using magnetic field. Aluminum 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In the present work, the study was conducted on EDM machined aluminum 6061 alloy with aluminum powder added in EDM oil and using magnetic field to analyze the effect of machining parameters on surface roughness, recast layer thickness and surface morphology. The input machining parameters, namely peak current, pulse on duration, pulse off duration, magnetic field and concentration of powder have been varied during the MFAPM-EDM process. Box–Behnken design approach of response surface methodology (RSM) was employed for experimental design to carry out the experiments. Quadratic model for predicting the surface roughness and recast layer thickness was developed using analysis of variance and regression analysis. Improvement in surface roughness and recast layer thickness were observed on machining with MFAPM-EDM process. Surface roughness and recast layer thickness were mostly influence by peak current and pulse on duration followed by concentration of powder and magnetic field. The surface morphology witness lesser cracks, voids, crater and molten debris particles present on the surface of machined aluminum 6061 alloy.

Assessing desalination pretreatment conditions towards pilot scale‐up using Box‐Behnken experimental design

AbstractThe purpose of this study is to optimize the operating conditions in batch mode using Box‐Behnken Design (BBD), for the coagulation‐flocculation line sizing prior the sand filter in the pilot scale. Three coagulants were employed to achieve a high turbidity removal with a low concentration of residual metals. The results showed that the best turbidity removal was obtained with FeCl3. Using BBD (15 experiments), the optimal parameters were: coagulant dose = 5.5 mg FeCl3/L, slow stirring time = 33 min and slow stirring velocity = 45 rpm, in these conditions, the turbidity removal reached 94.89% and the residual iron concentration was 0.449 mg/L. Regarding the model fit, the obtained R2 values were 99.67% for turbidity removal and 99.47% for residual iron concentration. The optimum conditions obtained from this study could be scaled up and applied to desalination plants. BBD approach is of great interest because it allows the prediction of the response value without performing experiments.

Optimization of process parameters in magnetic field assisted powder mixed EDM of aluminium 6061 alloy

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is a variant of EDM process where magnetic field coupled with electric field is used with addition of fine powder in dielectric to improve the surface quality, machining rate and stability of the process. Aluminium 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In this present work, parametric study and optimization was carried out on MFAPM-EDM machined Aluminium 6061 alloy. In this study, process parameters such as discharge current (IP), spark duration (PON), pause duration (POFF), concentration of powder (CP) and magnetic field (MF) were considered to analyze the effect on material erosion rate (MER) and electrode wear rate (EWR). Box Behnken design approach based on response surface methodology (RSM) was utilized for performing the experiments. Quadratic model to predict the MER and EWR were developed using response surface methodology. Discharge current has most significant effect of 50.176% and 36.36% on MER and EWR, respectively among all others process parameters. Teacher-learning-based optimization (TLBO) was employed for determining the optimal process parameters for maximum MER and minimal EWR. The results obtained with TLBO was compared with well-known optimization methods such as genetic algorithm (GA) and desirability function of RSM. Minimum EWR (0.1021 mm3/min) and maximum MER (30.4687 mm3/min) obtained using TLBO algorithm for optimized process parameters was found to better as compared to GA and desirability function.

Experimental investigations on high precision abrasive waterjet cutting of natural fibre reinforced nano clay filled green composites

The present investigation focused on abrasive waterjet cutting (AWJC) of natural fibre reinforced nano clay filled polyester composites with the objectives of maximizing material removal rate ( MRR) and minimizing the kerf taper ( KT) and surface roughness ( Ra). The influence of nano clay addition, traverse speed (TS), jet pressure (JP) and stand-off distance (SOD) on the AWJC characteristics of fabricated composite laminates are investigated. The natural fibre reinforced composite (NFRC) laminates are fabricated through hand lay-up technique through varying the wt% of nano clay fillers (0, 1 and 2). The AWJC experiments are planned and rigorous experiments were performed by adopting box-behnken design approach. The relative consequence of process variables on response features and quadratic regression models were assessed through analysis of variance (ANOVA). Further, multiple response optimization is carried out using statistical desirability technique to enhance the cut quality characteristics. The optimal AWJC parameters such as JP of 316.24 MPa, SOD of 2 mm and TS of 304.24 mm/min with 1.15 wt% of nano clay addition are determined. Microstructure of cut surface is examined to ascertain the morphological behaviour of AWJC surfaces with different processing conditions.