Grey-based Taguchi Method Research Articles

Optimization of Process Parameters of Friction Stir Welding of AA 6082-T6 Using Grey based Taguchi Method

Optimization of Process Parameters of Friction Stir Welding of AA 6082-T6 Using Grey based Taguchi Method

The Multi-Response Optimization of Machining Parameters in the Ultrasonic Assisted Deep-Hole Drilling Using Grey-Based Taguchi Method

The Multi-Response Optimization of Machining Parameters in the Ultrasonic Assisted Deep-Hole Drilling Using Grey-Based Taguchi Method

Multi-Objective Optimization of Photochemical machining of Inconel 601 using Grey Relational Analysis

Photochemical machining (PCM) is one of the least well-known nonconventional machining processes. The measure of performance is undercut (UC) and material removal rate (MRR). In this paper, the use of grey-based Taguchi method for optimization of the PCM process parameters in Inconel 601 etching with consideration of multiple output parameters is reported. In this new approach, the grey relational analysis is adopted to solve the PCM process. A grey relation grade obtained from the grey relational analysis is used as the performance characteristic. The optimal process parameter is determined by using parameter design proposed by the Design of Experiment (Full Factorial Method). Experimental results shown that, the optimal PCM process parameters are Temperature 47°C, Concentration 800gm/liter, and Time 5 minute in Inconel 601 etching to get optimal output for undercut and material removal rate.

Optimization of operating parameters for abrasion of areca sheath reinforced polymer composite: grey based Taguchi approach

Taguchi method has been widely and successfully used for more than two decades to improve the quality and performance of the product. In this research article, grey-based Taguchi method was implemented to optimize the operating parameters of dry sliding abrasive wear behavior of areca sheath fiber reinforced polyvinyl alcohol composites. Composites were prepared by incorporating randomly oriented benzyl chloride-modified areca sheath fibers taking 10, 20 and 30 wt% and experiments were conducted according to Taguchi’s L27 orthogonal array by considering three factors and three levels affecting the abrasion process using pin-on-disc apparatus. Grey relational analysis was utilized to optimize the multi-response tribological parameters. Analysis of variance was utilized to determine the importance of factors affecting wear the most. The specific wear rates for all the composites were also compared and discussed. The optimum process parameter which gives the best multiple response characteristics was found to be load 15 N, sliding velocity 0.392 m/s and filler content of 30 wt%. An improvement of 4.19% in GRG was observed after confirmation test which proves that the multiple performance characteristics of the natural fiber reinforced polymer composites can be adequately enhanced by this technique. Scanning electron micrographs were obtained at the optimum setting to support the findings.

Enhancement of the electrical performance of a printed organic thin film transistor through optimization of calendering process

Abstract The surface roughness of a gate dielectric layer has a large effect on the electrical performance of a printed OTFT (Organic Thin Film Transistor). In this study, a treatment process called calendering is proposed to improve the electrical performance of a printed OTFT by reducing the surface roughness of the gate dielectric layer. Bottom-gate, bottom-contact structural p-type OTFT samples were fabricated by gravure printing (gate electrode and gate dielectric), inkjet printing (source/drain electrodes), and spin coating (p-type channel). Various calendering process conditions composed of temperature, speed, and nip pressure were applied in the fabrication process. Then the calendering process was optimized using the grey-based Taguchi method. For validation of the proposed method, surface roughness of the gate dielectric layer and electrical performance of the non-calendered and calendered OTFT samples were compared and analyzed. The experimental results show a significant improvement that is a 15.92% decrease in the surface roughness, a 15.46% increase in the on-off ratio, and a 30.50% increase in the field-effect mobility.

A novel integrated SMED approach for reducing setup time

One of the shortcomings of the conventional single-minute exchange of die (SMED) method is that the improvements are made only upon the machine to reduce setup times. Although most of the setup activities involve operators, they are not considered adequately in this method. In workplaces with non-ergonomic setup systems, operators are exposed to different ergonomic risks, and thus, muscle fatigue is a problem for them. During the setup activities, muscle fatigue increases the setup times and risks of work accidents. In this study, the muscle fatigue assessment (MFA) method, also known as the Sue Rodgers method, was integrated into the conventional SMED method in order to evaluate the ergonomic risks in setup activities. Since the tools of the conventional SMED method are insufficient to shorten setup times, the grey-based Taguchi method, which consists of multiresponses such as setup time and fatigue risk, has been used for a setup activity. This method allows the determination of the process factor levels to minimize these responses. A form has also been developed for the integrated SMED method, which is called the Setup Observation and Analysis Form. The developed integrated SMED method based on the Sue Rodgers muscle fatigue assessment method and grey-based Taguchi method has been applied to a CNNx machine in a factory producing aluminum profiles. The overall setup time has been reduced to 73.5 min from 196 min, which indicates a total of 122.5 min and 62.5% improvement. With the conventional SMED method, the setup time is reduced to 101 min, whereas with the new approach, the setup time is reduced further to 21.5 min.

Using an Optimized Calendering Process with a Grey-Based Taguchi Method to Enhance the Performance of a Printed OTFT

Using an Optimized Calendering Process with a Grey-Based Taguchi Method to Enhance the Performance of a Printed OTFT

Optimization of Cutting Parameters, Condition and Geometry in Turning AISI 316L Stainless Steel Using the Grey-Based Taguchi Method

Optimization of Cutting Parameters, Condition and Geometry in Turning AISI 316L Stainless Steel Using the Grey-Based Taguchi Method

Optimisation of Machining Parameters in Turning AISI 304L Stainless Steel by the Grey-Based Taguchi Method

Optimisation of Machining Parameters in Turning AISI 304L Stainless Steel by the Grey-Based Taguchi Method

Approach to optimizing printed conductive lines in high-resolution roll-to-roll gravure printing

Roll-to-roll gravure printing has recently gained considerable interest regarding its application for manufacturing printed electronics, owing to its potential for processing large areas at low costs with high throughput. The geometry of the printed lines depends mainly on the process parameters. Unfortunately, missing areas and well-defined line widths have opposite tendencies. This paper presents a multi-response optimization process for printing high-resolution conductive lines using roll-to-roll gravure printing. Our optimization is based on grey relational analysis and an analysis of variance in conjunction with the Taguchi method, which uses an orthogonal array. Together, these techniques are used to optimize the printed pattern geometry and missing areas. Furthermore, we investigate several parameters for roll-to-roll gravure printing, such as ink viscosity, printing speed, and nip pressure, and the effect of these parameters on the line width, thickness, and missing areas of the printed pattern. Experiments were conducted to evaluate the proposed method, and the results of this evaluation demonstrate an improvement to the well-defined line width, thickness, and continuity of conductive lines under optimal parameter settings using the proposed grey-based Taguchi method. Taguchi method is used to study the effect of gravure printing on missing area, line width, and thickness.Grey relational analysis is used to determine the optimal combination of processing parameters.The optimal case are confirmed and compared to initial case and the best case from Taguchis design.

Integration of grey-based Taguchi method and principal component analysis for multi-response decision-making in Kansei engineering

This paper presents a hybrid method to determine the optimum combination of product form features in Kansei engineering. This method integrates the Taguchi method and grey relational analysis (GRA) coupled with principal component analysis (PCA). Experiments are performed on a variety of passenger car form designs. The Taguchi's L27 OA is chosen to design the experiments and to generate the car silhouettes as design samples. GRA is used to solve the multi-response optimisation problem, while PCA is used to assign the weighting values of relevant Kansei responses. The results show that the hybrid method was able to solve the complexity trade-off encountered in the decision-making process of multi-response optimisation using an economical and effective experimental design method. The method also has the capability in determining the optimum combination of product form features and generating an optimised car form design which accommodates the multi-Kansei need of consumers in a systematic manner. [Submitted: 28 June 2014 ; Revised 5 March 2016; Accepted: 28 September 2016]

Application of entropy measurement technique in grey based Taguchi method for optimization of MIG welding process parameters

We seldom realized that without this form of metal work, many structures would cease to be in existence. A skilled journeymen welder joins metal in such a way that it is not able to be parted unless it is cut. Welding is an absolutely essential technique used in various industries like automotive industry, construction industry as well as in the aviation industry. Hence welding process parameters are required to be optimized for their responses or welding characteristics. This study incorporates entropy measurement technique based on grey Taguchi method to analyze multiple quality characteristic optimization of metal inert gas welding of low carbon steel plates. For this study, four control variables are selected current, voltage, gas flow rate and wire feed rate and analysing their effect on the four quality characteristics ultimate tensile strength, elongation %, bending strength and hardness of the weldments have been investigated in this paper. In order to optimize the multiple quality characteristic of the MIG welding, grey relational analysis coupled with entropy measurement method has been employed. Using entropy measurement method, value of weight corresponding to each quality characteristic has been assigned, so that the importance can be properly determined. Using the theory of grey relational analysis, these have been accumulated to calculate the overall grey relational grade. Signal to Noise ratio (S/N ratio) is applied to find the optimal parameter setting. To determine the contribution of MIG welding process parameters, Analysis of variance (ANOVA) on grey relational grade has been calculated. The confirmatory test also has been done for verifying the results. A foresaid methodology has been found fruitful in the cases where simultaneous optimization of huge number of responses is required.Keywords: Metal Inert Gas (MIG) Welding, Grey-Taguchi Method, Entropy Measurement Technique, Analysis of variance (ANOVA), S-N ratio.

Optimization of MQL flow rate for minimum cutting force and surface roughness in end milling of hardened steel (HRC 40)

The present work focuses on the performance modeling of hard milling to attain an optimum parameter setting for the minimum cutting force and surface roughness. Furthermore, it was attempted to compute the minimum quantity lubricant flow rate precisely, besides the cutting speed and table feed rate, by adopting Grey-based Taguchi method and composite desirability function. The experimental data was collected by end milling of hardened AISI 4140 steel using carbide cutter under dry and minimum quantity lubrication conditions according to Taguchi L 16 orthogonal array. The predictive model of the responses was formulated by using response surface methodology. The analysis of variance revealed that the table feed has the maximum influence on cutting force, and the flow rate of lubricant has the highest effect on surface roughness. The parameter setting at lower table feed, higher cutting speed, and 150-ml/h lubricant flow yield the minimum value of the responses. Finally, the results of confirmation test verified the adequacy and supremacy of the optimization models; however, Grey-based Taguchi method induced a better optimization.

Multi objective optimization of clinching joints quality using Grey-based Taguchi method

Clinching joint quality and functionality may have undesirable features because of the choice of the forming process parameters. In fact, there are different factors controlling the mechanical connection strength such as the tools’ geometry and the joint final shape. This paper presents the implementation of the Taguchi-based Grey optimization of the mechanical clinching with fixed dies for dissimilar materials (Aluminum alloy 7075 and Mild Steel) to derive the optimal process parameters combination that leads to a high strength connection subjected to multiple characteristics, namely, the bottom thickness, the interlock length, and the neck thickness of the joint. LS-DYNA explicit and implicit finite element (FE) software was used to simulate the process in order to evaluate the joint strength by loading the sheets vertically. Taguchi’s L27 orthogonal array design and the notion of signal-to-noise (S/N) ratio were utilized to obtain the objective function. Analysis of variance (ANOVA) showed the importance of factors on overall output. The output of the study provided the optimal geometrical parameters of the punch, die, and blank holder. Indeed, the die groove height, die diameter, punch diameter, punch corner radius, and clearance between punch and blank holder were found to be the most influential parameters on the bottom and neck thicknesses. In addition, the output indicated that when bottom thickness or neck thickness increased, the interlock decreased.

Simultaneous optimization of smoke and NOx emissions in a stationary diesel engine fuelled with diesel–oxygenate blends using the grey relational analysis in the Taguchi method

The objective of the present study is to optimize the smoke and NOx emissions simultaneously in a diesel engine fuelled with stationary diesel–oxygenate blends using the grey based Taguchi method.

Parametric Optimization of MIG Welding on 316L Austenitic Stainless Steel by Grey-based Taguchi Method

In the present work, visual inspection and X-ray radiographic test has been conducted in order to detect surface and sub-surface defects of weld specimens made of AISI 316L austenitic stainless steels. Effect of current, gas flow rate and nozzle to plate distance on quality of weld in metal inter gas arc welding of AISI 316L austenitic stainless steel has been studied in the present work through experiments and analyses. Butt welded joints have been made by using several levels of current, gas flow rate and nozzle to plate distance. The quality of the weld has been evaluated in terms of yield strength, ultimate tensile strength and percentage of elongation of the welded specimens. The observed data have been interpreted, discussed and analyzed by using Grey - Taguchi methodology.

Grey-based Taguchi method for optimisation of hot forging of connecting rod

In this paper, three dimensional finite element analysis has been carried out using FEM-based DEFORMTM 3D software on hot forging of connecting rod. The influence of design parameters and process parameters are investigated for the responses like effective strain rate and forging load during forging operation. In order to optimise both the responses simultaneously, grey relational analysis (GRA) embedded with Taguchi method is employed. Grey relational grade is used as a performance index to determine optimal setting of process parameters for both the responses simultaneously. Analysis of variance (ANOVA) is employed to determine significant parameters. Process parameters such as flash thickness, flash width, and corner radii are found to be the most significant parameters affecting grey relational grade. Optimal process setting leading to a higher effective strain rate with the least forging load has been verified through a confirmation experiment for validation of the results. [Received 15 October 2015; Revised 25 February 2016; Accepted 13 March 2016]

Taguchi method for optimization of fabrication parameters with mechanical properties in fiber and particulate reinforced composites

In this paper, the grey-based Taguchi method was used to optimize the fabrication parameters with mechanical properties (multiple performance characteristics) in roselle fiber with (5 % wt) Coconut shell powder (CSP) reinforced vinyl ester (RFRVE) composites. Composite plates were prepared based on the Taguchi’s L27 orthogonal array using hand lay-up technique at room temperature. Fabrication parameters namely fiber length, fiber content, and fiber diameters were optimized based on the grey relational grade (GRG) as performance index obtained from the grey relational analysis to get the maximum level of multiple performance characteristics such as the tensile strength, the flexural strength, and the impact strength. The results show that the fiber content is the most significant fabrication parameter which greatly affects the mechanical properties of RFRVE composite compared to the fiber length and the fiber diameter. It was proved that the multiple performance characteristics of the plant based natural fiber and particle reinforced polymer composites can be effectively improved by this method.

Taguchi method for optimization of fabrication parameters with mechanical properties in sisal fibre–vinyl ester composites

In this paper, the grey-based Taguchi method was used to optimize the fabrication parameters with mechanical properties multiple performance characteristics (MPC) in sisal fibre-reinforced vinyl ester (SFRVE) composites. Composite plates were prepared based on the Taguchi’s L27 orthogonal array using hand lay-up technique at room temperature. Fabrication parameters, namely fibre length, fibre content and fibre diameters were optimized based on the grey relational grade as performance index obtained from the grey relational analysis to get the maximum level of MPC such as the tensile strength, the flexural strength and the impact strength. The results show that the fibre content is the most significant fabrication parameter which greatly affects the mechanical properties of SFRVE composite compared to the fibre length and the fibre diameter. It was proved that the MPC of the plant-based natural fibre-reinforced polymer composites can be effectively improved by this method.

Mathematical modeling and multi-criteria optimization of rotary electrical discharge machining process

In this paper, mathematical modeling of three performance characteristics namely material removal rate, surface roughness and electrode wear rate in rotary electrical discharge machining RENE80 nickel super alloy is done using regression approach. The parameters considered are peak current, pulse on time, pulse off time and electrode rotational speed. The regression approach is very much effective in mathematical modeling when the performance characteristic is influenced by many variables. The modeling of these characteristics is helpful in predicting the performance under a given set of combination of input process parameters. The adequacy of developed models is tested by correlation coefficient and Analysis of Variance. It is observed that the developed models are adequate in establishing the relationship between input parameters and performance characteristics. Further, multi-criteria optimization of process parameter levels is carried using grey based Taguchi method. The experiments are planned based on Taguchi's L9 orthogonal array. The proposed method employs single grey relational grade as a performance index to obtain optimum levels of parameters. It is found that peak current and electrode rotational speed are influential on these characteristics. Confirmation experiments are conducted to validate optimal parameters and it reveals the improvements in material removal rate, surface roughness and electrode wear rate as 13.84%, 12.91% and 19.42% respectively.