Optimal Combination Of Process Parameters Research Articles

Experimental Investigation of the Effect of Process Parameters on Material Removal Rate and Surface Finish

Lapping is a finishing process used especially for removing the material, achieving finer surfaces, correcting minor imperfections and maintaining close tolerances. This process may takes place due to the relative motion between the work material, slurry and lapping plate. This study is done by conducting a series of experiments based on taguchi design of experiments and calculating material removal rate and surface roughness. This study explains about effect of the parameters on material removal rate and surface finish. The final step of this process is to find out the optimum combination of process parameters to determine the material removal rate and the surface finish.

The Influence of SLS Process Parameters on the Tensile Strength of PA2200 Powder

In the process of selective laser sintering, the forming parameters will affect the dimensional accuracy and performance of the forming parts. At present, there is no reference standard for the optimal forming parameters of PA material. Aiming at this problem, the three factors of laser power, scanning pitch and scanning speed are analyzed, and the influence of the tensile strength of PA2200 material forming parts is analyzed. Through theoretical and experimental analysis, the optimal combination of process parameters is obtained by orthogonal experiment. The best combination of parameters is laser power 40W, scanning speed 3000mm/s, scanning pitch 0.4mm, and tensile strength up to 46.42MPa.

Modeling and optimization of fused deposition modeling (FDM) process through printing PLA implants using adaptive neuro-fuzzy inference system (ANFIS) model and whale optimization algorithm

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) technique for developing complex features and geometries within the shortest possible time as per customer needs. Nowadays, the customization of biomedical parts is becoming possible due to the increasing accuracy and enhanced ability of FDM machines to control the process parameters. The control on surface quality of parts produced by FDM process is of prime concern for the researchers, which are induced due to the stair steps on sloping surfaces, and needs addressing. In addition, to meet customer demands rapidly, the FDM part build time must be reduced without much compromising the strength of the parts necessary for specific applications. In the same context, this paper presents the effect and control of FDM process parameters, i.e., layer thickness, raster angle, infill density and internal structure, on surface roughness, build time and compressive strength of developed biomedical implant parts. The face-centered central composite design is employed to consummate the experimental trials, and experimental data are used to establish an adaptive neuro-fuzzy inference system (ANFIS) model for predicting the surface roughness, build time and compressive strength with respect to changes in FDM process parameters. At the end, whale optimization algorithm (WOA) has been applied to minimize surface roughness, minimize build time and maximize compressive strength simultaneously. Then, the optimal solutions obtained from WOA methodology have been compared with ANFIS predicted results. The results reveal that ANFIS-WOA methodology provides optimal combination of FDM process parameters accurately.

Analysis and Multi-Objective Optimization for Reducing Energy Consumption and Improving Surface Quality during Dry Machining of 304 Stainless Steel.

Cutting quality and production cleanliness are main aspects to be considered in the machining process, and determining the optimal cutting parameters is a significant measure to reduce energy consumption and optimize surface quality. In this paper, 304 stainless steel is adopted as the research objective. The regression models of the specific cutting energy, surface roughness, and microhardness are constructed and the inherent influence mechanism between cutting parameters and output responses are analyzed by analysis of variance (ANOVA). The desirability analysis method is introduced to perform the multi-objective optimization for low energy consumption (LEC) mode and low surface roughness (LSR) mode. Optimal combination of process parameters with composite desirability of 0.925 and 0.899 are obtained in such two modes respectively. As indicated by the results of multi-objective genetic algorithm (MOGA), genetic algorithm (GA) combined with weighted-sum-type objective function and experiment, the relative deviation values are within 10%. Moreover, the results also reveal that the feed rate is the most significant factor affecting the three responses, while the correlation of cutting depth is less noticeable. The effect of low feed rate on microhardness is primarily related to the mechanical load caused by extrusion, and the influence at high feed rate is determined by plastic deformation.

Optimization Using Response Surface Methodology (RSM) for Biodiesel Synthesis Catalyzed by Radiation-Induced Kenaf Catalyst in Packed-Bed Reactor

In this study, continuous transesterification of refined palm oil by using radiation-induced kenaf denoted as anion exchange kenaf catalyst in a packed-bed reactor was developed. The application of full factorial design and response surface methodology (RSM) based on the central composite design (CCD) was used to design the process and analyzed the effect of reactor operating variables such as packed bed height, the molar ratio of oil to ethanol and volumetric flow rate on the production of fatty acid ethyl ester (FAEE). The statistical analysis results showed that all three operating parameters affect the reaction efficiency significantly. The optimum conditions were determined to be 9.81 cm packed bed height, a molar ratio at 1:50, and a volumetric flow rate of 0.38 mL min−1. Three tests were carried out to verify the optimum combination of process parameters. The predicted and actual values of molar conversion fatty acid ethyl ester (FAEE) molar conversion were 97.29% and 96.87%, respectively. The reusability of kenaf fiber-based catalysts is discussed with a specially highlighted on fiber dissolution, leaching, and fouling. Nevertheless, the impurities absorption properties of anion exchange kenaf catalyst towards biodiesel production could eventually simplify the biodiesel purification steps and cost. In sum, anion exchange kenaf catalyst shows the potential commercial applications to transesterification of FAEE in a packed-bed reactor.

Influence of processing parameters of selective laser melting on high‐cycle and very‐high‐cycle fatigue behaviour of Ti‐6Al‐4V

AbstractOrthogonal experiment design together with the analysis of variance was used to examine the processing parameters (laser power, scan speed, layer thickness and hatch spacing) of selective laser melting (SLM) for superior properties of SLM parts, in which nine groups of specimens of Ti‐6Al‐4V were fabricated. The results clarify that the influence sequence of individual parameter on the porosity is laser power > hatch spacing > layer thickness > scan speed. Ultrasonic fatigue tests (20 kHz) were conducted for the SLMed specimens in high‐cycle fatigue (HCF) and very‐high‐cycle fatigue (VHCF) regimes. The S‐N data show that the fatigue strength is greatly affected by the porosity: the group with the smallest porosity percentage having the highest fatigue strength in HCF and VHCF regimes. Then, the tests on the validation group were performed to verify the optimal combination of SLM processing parameters. Moreover, the observations by scanning electron microscopy revealed that fatigue cracks initiate at lack‐of‐fusion defects in the cases of surface and internal crack initiation.

Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276

Abrasive waterjet (AWJ) milling is a rapidly evolving research topic in the development of unconventional methods for machining high-strength materials without affecting their physical and thermal properties. It is considered as a promising technique for machining milling pockets in Hastelloy C-276. In the present study, the AWJ milling behaviour of Hastelloy C-276 was examined with the purpose of evaluating the performance parameters, namely the material removal rate and surface roughness (Ra). The considered input process parameters included the waterjet pressure, step over, traverse rate, and abrasive flow rate. The response surface methodology with a Box–Behnken design was used to perform the experiments, which involved 29 machining runs. Analysis of variance was used to identify the significant parameters of the machining process, and the optimal process parameter combination for achieving a high material removal rate and low surface roughness was established with the aid of response surface graphs. Multi-response optimisation based on grey relational analysis was also performed taking into consideration the overall output response. The waterjet pressure and traverse rate were identified as the primary determinants of the material removal rate, whereas the step over was the predominant factor of the surface roughness. The selected AWJ milling conditions based on grey relational analysis approach were examined using surface morphology, surface topography of milled pockets on Hastelloy C-276.

Cutting of polyethylene terephthalate (PET) film by 355 nm nanosecond laser

Special-shaped polyethylene terephthalate (PET) films are widely used in the electronics industry, and high-quality cuts is one of the core parameters for expanding scope of PET applications. In this article, 355 nm nanosecond laser is used to obtain a high-quality PET cuts. First, the laser cutting quality evaluation system based on the straightness, the width of the cuts, and the size of the heat affected zone (HAZ) was defined. Then, the influence of laser cutting parameters on the cut’s quality was analyzed by 3 factors and 5 level orthogonal experiment, and high-quality cuts (width 25.2 ± 3.6 μm, HAZ 18.4 ± 2.2 μm, straightness 2.9 ± 0.32 μm) was obtained under the optimal process parameter combination. Finally, the interaction mechanism between nanosecond UV laser and PET film with heating carbonization and hot melt as the core was explored, and the effect of laser cutting process parameters on the quality of the cuts was analyzed based on this mechanism.

Multi-objective Optimization of Injection Process Parameters Based on EBFNN and NSGA-II

Taking the process parameters and quality index data obtained from the optimal Latin hypercube test of a front hood inner panel as sample data, this paper constructs an EBFNN approximate model by combining the NSGA-II multi-objective optimization algorithm to perform multi-objective optimization of injection molding process parameters, obtained Pareto solution set for volume shrinkage and warp during ejection. Comparing the Moldflow numerical simulation results of the four relatively optimized Pareto solutions, the optimal combination of process parameters is obtained. The optimized volume shrinkage and warp deformation reduced by 50.518% and 39.845% respectively, which verified the reliability and practicability of this method, and had certain practical reference significance for the optimization of injection molding process of other plastic parts.

Artificial Intelligence System Approach for Optimization of Drilling Parameters of Glass-Carbon Fiber/Polymer Composites

In recent times, the study on machining characteristics of combined (hybrid) fiber polymer composites has drawn a remarkable research attention because of its emerging industrial applications. The present study focuses on the drilling of hybrid glass-carbon fiber reinforced (GCFR) epoxy composites fabricated using hand layup technique. The machining characteristics were considered in the drilling of GCFR composites which include thrust force, torque, delamination factor and surface roughness. The influence of the drilling process parameters such as spindle speed, drill diameter and feed rate on the characteristics are studied. To avoid the confounding effect of the individual optimized characteristics, an artificial intelligence system i.e. fuzzy inference system approach is adopted. The fuzzy inference system transformed all the performance characteristics of drilled hybrid composites into a multi response performance index (MPI) and optimized the MPI at the common factor level setting. The optimal combination of process parameters for minimum thrust force, torque, delamination factor and surface roughness found to be: speed 3000 RPM, drill diameter 5 mm and the feed rate 50 mm/min. The analysis of variance results show that drill diameter is the most significant parameter followed by feed rate and speed. Further, a theoretical model was proposed for the estimation of MPI and found that an average absolute error of 14.8% with respect to the experimental MPI data is obtained.

Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process

The process enhancement plays a vital role in the modern machining techniques during machining of newer materials such as titanium alloys. In the present work, a research endeavor was made to examine the effects of process parameters in laser beam machining process while drilling holes over Titanium (Ti-6Al-4V) alloy under Taguchi approach of experiments. Nozzle distance, power, focal length and gas pressure were chosen as the input process parameters to assess the dimensional accuracy quality measures such as roundness and ovality in laser beam machining process. It was found that power has the most significant impact on determining the dimensional accuracy. 1.2 mm (ND), 2 mm (L), 4 bar (GP) and 2 kW (J) has been chosen as optimal process parameters combination for obtaining better dimensional accuracy among the selected process parameters. It was also observed that the machinability could be highly influenced with lower peak power.

Parametric influences of fiber laser micro-machining for the generation of micro-channels on PMMA

Fiber laser micro-channeling on polymethyl methacrylate (PMMA) workpiece has been carried out to determine the effect of process parameters as well as optimum values of the responses, i.e., cut width and depth of the fabricated micro-channels. Response surface methodology-based analysis has been carried out by conducting experiments as per experimental design by varying scan speed of 10–30 mm/s; pulse frequency from 50 to 90 kHz; laser power of 5–15 W and the number of pass from 1 to 5. The mechanism behind the fiber laser-fabricated micro-channels on PMMA at 1064 nm wavelength has been discussed and analyzed. A sensitivity analysis of the process parameters on cut width and depth has also been carried out to determine the critical parameter influencing the micro-channel geometry. The experimental results show that the sensitiveness of both cut width and depth are maximum for the number of passes as compared to the other process parameters. Finally, at an optimum combination of process parameters, the optimal values of cut width, and depth are achieved as 145.34 µm and 445.50 µm, respectively. Concerning the optimal values of the responses, the mean percentage errors are calculated below 5% from the optimized combination of process parameters. The present research work provides a technical guideline of fiber laser processing on PMMA at a fundamental wavelength.

Stretchability improvement of flexiable electronics by laser micro-drilling array holes in PDMS film

The preparation of micro-holes through flexible substrate is an effective method for improving stretchability of flexible electronics. Quantitative fabrication of micro-holes on polydimethylsiloxane (PDMS) film was achieved by using the 355 nm nanosecond laser. An Orthogonal experiment with 3-factors and 5-levels was designed to discuss the influence of processing parameters (pulse repetition frequency, drilling speed, and drilling times) on the quality of micro-holes from the view of diameter, roundness, and heat-affected zone (HAZ). It was found that heat-induced carbonization is an inner mechanism during the nanosecond laser micro-drilling process of PDMS. The optimal combination of processing parameters was obtained, the pulse repetition frequency was 180 kHz, the drilling speed was 0.015 mm/min, and the drilling times was 75. While the smallest micro-hole diameter (29.6 ± 3.4 μm) and HAZ (8.4 ± 2.7 μm) were obtained, the best micro-hole roundness (1.7 ± 0.6 μm) was achieved. The tensile limit of flexible electrode prepared with the array micro-hole PDMS (diameter 29.6 ± 3.4 μm, center distance 60 μm) was increased from 16% to 38%, compared with that being prepared with the planar PDMS.

Multi Criteria Decision Making of Vibration Assisted EDM Process Parameters on Machining Silicon Steel Using Taguchi-DEAR Methodology

In the present scenario, an endeavour is being utilized to associate the low frequency vibrations with electrical discharge machining process for enhancing the process mechanism. The process parameters of such process should be optimized to improve the quality measures. In the present study, Taguchi- Data Envelopment Analysis based Ranking(DEAR) based multi criteria decision making has been proposed to obtain optimal combination process parameters on machining silicon steel in low frequency vibration assisted EDM process. From the experimetal investigations, the optimal process parameters combination has been found was found as I (6A),Ton (50 μs), Toff (25 μs) and F (256 Hz) among the chosen parameters in the machining process. The vibration frequency is more dominant factor in ultrasonic vibration assisted EDM process owing to importance in flushing mechanism. The better surface topography has been obtained with higher micro hardness and lower micro cracks over the machined silicon steel under optimal process parameters combination.

Potassium Chloride-Modified Urea Phosphate with Response Surface Optimization and Its Application Effect on Maize in Saline-Alkali Soil.

Urea phosphate (UP) is an acidic compound fertilizer, which significantly improves the low efficiency of P application caused by high pH in saline-alkali soil. In this study, urea phosphate potassium (UPK) was prepared by adding potassium chloride (KCl) to modify urea phosphate (UP) and the optimal combination of the synthetic process parameters was obtained using the response surface methodology at a four-variable, three-level experiment Box–Behnken design. Parameters such as the reaction temperature, KCl molar number, reaction time, and concentration of phosphoric acid were included for optimization. The thermostability, crystal structure, and microscopic morphology of UPK were measured by thermogravimetric analysis (TGA), X-ray diffraction (XRD), and scanning electron microscopy (SEM), respectively. The fertilizer efficiency was validated in an experiment on maize grown in pots containing saline-alkali soil. The highest K2O content and UPK yield were obtained by using the following parameters: reaction time of 60 min, KCl of 0.32 mol, reaction temperature of 78 °C, and phosphoric acid concentration of 70%. Under optimal conditions, the predicted K2O value content and UPK yield were 3.51% and 69.8%, respectively. The experimental K2O content and UPK yield were 3.42 ± 0.35% and 67.58 ± 1.25%, respectively, which confirmed the strength of the predicted model. This model can be used as an effective tool to predict the K2O content and yield in UPK. Characterizations showed that KCl was uniformly distributed in UPK and its fluidity was effectively improved as observed in the angle-of-repose results. Compared to a conventional phosphorus fertilizer diammonium phosphate (DAP), the yield, total P use efficiency, soil available phosphorus content, and soil acid phosphatase activity of UPK increased significantly by 25.58, 174.5, 24.41, and 41.25%, respectively, and the soil pH on UPK treatments decreased by 3.98% significantly. In conclusion, this novel technology to modify UP by using KCl has an enormous potential for large-scale applications to satisfy the increasing demand for UP fertilizers on saline-alkali soil.

Study on Simulation of Injection Process and Optimization of Process Parameters of Polypropylene Bottle Embryo

The purpose of this paper is to obtain the best process parameters of polypropylene bottle injection molding. This paper obtained the gating system of polypropylene bottle embryo by using MOLDFLOW according to the structural characteristics of polypropylene bottle embryo, and optimized the process parameters by using taguchi method within the reasonable range of process parameters. In this paper, six parameters about time, pressure and temperature were selected as factors for the mold flow analysis of polypropylene bottle embryo injection molding, and there were four levels in every factor. The volume shrinkage, sink index and residual stress in the first and second directions in the cavity were selected as evaluation indexes. In order to reduce evaluation indexes, the signal to noise ratio of each factor and each level were calculated, and the adjustable factors were adjusted to obtain the minimum evaluation indexes and optimal combination of process parameters. The optimum process parameters such as melt temperature 200°C, molding temperature 20°C, injection pressure 50Mpa, injection time 2.1s,dwell pressure 44Mpa, dwell time 40s were gained.

Study on surface roughness of zirconia ceramics in high efficient and precision grinding process

In order to solve the problem that the surface roughness of engineering ceramics is difficult to control, this paper studied the influencing factors of surface roughness of zirconia ceramic grinding. The effects of grinding depth, grinding wheel speed and workpiece feed rate on surface roughness were analyzed by the orthogonal experiments of zirconia ceramic grinding. On this basis, single factor experiments were carried out respectively, and the optimal combination of process parameters was analyzed. In addition, an empirical formula of surface roughness for the grinding of zirconia ceramics was established based on the experimental results. The results showed that the grinding depth had a great influence on the surface roughness, the grinding wheel speed effect was secondary, and the effect of the workpiece feed rate on the surface roughness was not very obvious. Compared with the measured value, the maximum relative error of the predicted value was less than 5%, which indicated that the empirical formula had a better prediction effect and provided a theoretical basis for reasonable selection of grinding parameters in actual processing.

Process parameters optimization of single-track laser cladding for 45 steel gear remanufacturing

In order to research the optimal combination of process parameters for the remanufacturing of 45 steel gear with RCF104 alloy powder, three-factor and five-level orthogonal experiments of laser power, scanning speed and powder feeding speed were carried out on 45 steel substrate. The best process parameters combination was selected by considering the shape coefficient of the cladding layer, dilution rate, cladding width and cladding height. The microstructure of the cladding layer was analyzed, the horizontal and vertical microhardness of the cladding layer was measured. The results show that the optimal combination of process parameters was laser power 448 w, scanning speed 6 mm/s, powder feeding speed 9.0369 g/min. The analysis of variance shows that the laser power and scanning speed were the main factors influencing the cladding width and the scanning speed had a significant influence on the cladding height and shape coefficient. The microstructure analysis of cladding layer shows that planar crystals, cellular crystals, columnar crystals, dendrites and equiaxed crystals changed gradually from bottom to top. The average microhardness of the cladding layer was 672.2HV, which was 3.08 times of the matrix hardness.

Linen Fabric-Jute Fabric-Fumed Silica-Epoxy Sandwich Laminate: AWJ Machining and Multi-Response Optimisation

Since fabric-polymer laminates are being used in several engineering applications, it is imperative to compute and analyse the performance of any novel fabric reinforced polymer laminates while machining. Given these perspectives, an endeavor has been made to formulate a polymer sandwich laminate by incorporating industrial by-product & natural fibres and to machine the sandwich laminate using Abrasive Water Jet (AWJ) machining. For enhancing the machining process, a multi-objective optimisation is employed. In this study 2 wt.% fumed silica added epoxy reinforced with linen fabric (3 layers) & jute fabric (2 layers) sandwich laminate is machined using AWJ machining and the optimal combination of machining parameters are predicted using Taguchi-grey relational technique for multi-response characteristics such as Material Removal Rate (MRR) and Kerf Inclination (KI). For multi-response optimisation the traverse speed, the standoff distance, and the abrasive flow rate are considered as input machining parameters. In AWJ machining, the MRR increases with traverse speed and abrasive flow rate. Whereas, passing of higher abrasive particles at higher traverse speed causes reduction in kerf inclination. Using Taguchi-grey relational analysis (GRA), the optimal combination of AWJ machining process parameters for maximum MRR and minimum kerf inclination is attained. For determining the greatest significant parameter in optimisation, ANOVA is carried out. The standoff distance has the highest influence on multi performance characteristics of AWJ machining of laminate followed by traverse speed and abrasive flow rate. The confirmation test revealed that the grey relation grade value has improved by 1.81% from predicted grey relation grade value.

Orthogonal Experimental Research on Dielectrophoresis Polishing (DEPP) of Silicon Wafer.

Silicon wafer with high surface quality is widely used as substrate materials in the fields of micromachines and microelectronics, so a high-efficiency and high-quality polishing method is urgently needed to meet its large demand. In this paper, a dielectrophoresis polishing (DEPP) method was proposed, which applied a non-uniform electric field to the polishing area to slow down the throw-out effect of centrifugal force, thereby achieving high-efficiency and high-quality polishing of silicon wafers. The principle of DEPP was described. Orthogonal experiments on important polishing process parameters were carried out. Contrast polishing experiments of silicon wafer were conducted. The orthogonal experimental results showed that the influence ratio of electric field intensity and rotation speed on material removal rate (MRR) and surface roughness was more than 80%. The optimal combination of process parameters was electric field intensity 450 V/mm, rotation speed 90 rpm, abrasive concentration 30 wt%, size of abrasive particle 80 nm. Contrast polishing experiments indicated that the MRR and material removal uniformity of DEPP were significantly better than traditional chemical mechanical polishing (CMP). Compared with the traditional CMP, the MRR of DEPP was increased by 17.6%, and the final surface roughness of silicon wafer reached Ra 0.31 nm. DEPP can achieve high-efficiency and high-quality processing of silicon wafer.