Optimum Values Of Process Parameters Research Articles

Optimasi Parameter Proses 3D Printing FDM Terhadap Akurasi Dimensi Menggunakan Filament Eflex

Fused Deposition Modeling (FDM) is a 3D Printing technique used to print products using filaments as material. The printed product has ideal geometric characteristics if it has meticulous size and perfect shape. One type of material that can be processed using 3D Printing FDM is flexible material. Research in terms of dimensional accuracy has been carried out on PLA and ABS materials. While research using flexible materials is still rarely done. From these problems, we need a study to get the process parameter settings on a 3D Printer machine that is optimal in obtaining dimensional accuracy using flexible materials. The research was carried out using the Prusa model DIY (Do It Yourself) 3D machine with FDM technology. The material used is Eflex type flexible filament with a diameter of 1.75 mm. The process parameters used in this study are flowrate, layer thickness, temperature nozzle, speed printing, overlap, and fan speed. Cuboid test specimens measuring 20 mm × 20 mm × 20 mm. Process parameter optimization using the Taguchi L27 Orthogonal Array method for dimensional accuracy testing. Optimal process parameter values for obtaining X dimension accuracy are 110% flowrate, 0.10 mm layer thickness, 210 °C nozzle temperature, 40 mm/s print speed, 75% overlap, and 50% fan speed. Y dimension is 120% flowrate, layer thickness 0.20 mm, nozzle temperature 230 °C, print speed 30 mm/s, overlap 75%, and fan speed 100%. As well as the Z dimension is 120% flowrate, layer thickness 0.30 mm, nozzle temperature 210 °C, print speed 30 mm/s, overlap 50%, and fan speed 100%.

An integrated model for process parameter adjustment to recover throughput shortage in semiconductor assembly: A case study

Purpose: Existing productivity improvements activities such as inventory buffer, overall equipment effectiveness (OEE) and total productive maintenance (TPM) do not analytically associate the throughput shortage with process parameters. The paper aims to develop and test an integrated model to recover the throughput shortage through process parameters adjustment in a semiconductor assembly.Design/methodology/approach: The mathematical model of planned throughput is developed as a function of input parameters in an integrated multiple process line. When the planned throughput does not meet the real-time throughput, the throughput shortage occurs. The planned throughput for the next day is summed with the throughput shortage from previous day and mathematical programming is used to find the optimum process parameter values. Findings: The throughput shortage is restored using mathematical programming for the subsequent day of planning. If there still exist throughput shortage, the additional throughput shortage will be carried forward for the subsequent day of planning where mathematical programming is used again to find the adjusted process parameters. The proposed optimization model in essentially a parametric model using input parameters of real-time data based on a normal distribution that is translated into a range of minimum and maximum using 95% confidence interval.Research limitations/implications: The adjusted input parameters in this model is based on the cycle time of three processes which are Die Attach, Wire Bond and Pre-Cap Inspection. Downtime and setup time are not subjected to adjustments.Practical implications: The mathematical programming computes optimum process parameters values to restore the throughput shortage where it correlates the process parameters and throughput shortage quantitatively rather than conventional method of throughput shortage recovery.Originality/value: The research addresses the process parameter adjustment to recover the throughput shortage in integrated multiple processes.

Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024.

It is hypothesized that the orientation of tool maneuvering in the milling process defines the quality of machining. In that respect, here, the influence of different path strategies of the tool in face milling is investigated, and subsequently, the best strategy is identified following systematic optimization. The surface roughness, material removal rate and cutting time are considered as key responses, whereas the cutting speed, feed rate and depth of cut were considered as inputs (quantitative factors) beside the tool path strategy (qualitative factor) for the material Al 2024 with a torus end mill. The experimental plan, i.e., 27 runs were determined by using the Taguchi design approach. In addition, the analysis of variance is conducted to statistically identify the effects of parameters. The optimal values of process parameters have been evaluated based on Taguchi-grey relational analysis, and the reliability of this analysis has been verified with the confirmation test. It was found that the tool path strategy has a significant influence on the end outcomes of face milling. As such, the surface topography respective to different cutter path strategies and the optimal cutting strategy is discussed in detail.

Decolourization of Reactive Dye from Aqueous Solution using Electrocoagulation: Kinetics and Isothermal Study

Abstract Reactive dyes are essential materials for the modern lifestyle due to rapid industrialization and urbanization, but they cause adverse effects on the environment. This research work aimed to decolourize the synthetic aqueous solution containing Reactive Black B (RBB) dye using electrocoagulation (EC) process with iron electrodes in batch reactor. The effect of operational parameters such as initial pH (3–9), the distance between electrodes (0.5–2 cm), current density (1.1–8.4 mA/cm2) and initial dye concentration (100–400 mg/L), was investigated in the presence of sodium chloride to maintain the conductivity of electrolytes. Under optimal value of process parameters, high decolourization (99.6%) was obtained at 25 min. The experimental data showed that pseudo-second order kinetics with a correlation coefficient (R 2 = 0.97) and Sips isotherm with a correlation coefficient (R 2 = 0.98) were found to be well fitted for kinetic and adsorption equilibrium models, respectively. The economic efficiency was also calculated on the basis of electrical energy consumption (EEC), specific electrical energy consumption (SEEC), and current efficiency, respectively. Moreover, characterization of EC generated sludge was also carried out by proximate analysis, IR spectra and XRD analysis. The results revealed that EC process using Fe electrode is quite efficient and clean process for decolourization of reactive dye from aqueous solution.

Optimization of turbidity removal by coagulation and flocculation process from synthetic stone cutting wastewater

Cutting industries produce large quantities of wastewaters with the high content of suspended solids and turbidity. The treatments of these wastewaters are important in preventing the environmental pollution. This study aimed to optimize the use of coagulation and flocculation process by the response surface methodology (RSM) method as an effective method for the abatement of turbidity-related challenges of such wastewater using coagulants of Alum and polyaluminum chloride. This study is an analytical-applied. The synthetic wastewater with a turbidity of 170 ± 2 NTU at each stage of the jar test was used. The effect of Alum and PAC application was evaluated and compared each other as a function of settling time (40–140 min), pH (2–8), speed (20–60 rpm), and the coagulant dose (0–200 mg/l). In this study, the central composite design (CCD) was utilized to experimental design, modeling, and optimization of the turbidity removal from a stone cutting wastewater. A total of 33 experiments were designed for each coagulant. Results showed that the optimal conditions for turbidity removal were settling time, initial pH, speed, coagulant dosage, 40.98, 7.47, 55.44, 163.56–56.62, 7.93, 34.55, and 199.53 for Alum and PAC, respectively. Under these optimal values of process parameters, the dye removal efficiency of 100% and 98.84% was observed for Alum and PAC, respectively. The sum of squares model showed that the quadratic model is the best option for empirical data with the highest correlation coefficient (R2 of 0.99 and 0.98 for Alum and PAC, respectively.) and P value < 0.0001 for both models. The models can adequately describe the prominent behavior of turbidity removal process. Although a high turbidity removal was observed for application of the both coagulants, in real-scale selection, each of them is related to the operator conditions. Moreover, further investigations should be considered to generalization of this work results to the real-stone cutting wastewater. Besides, the TSS challenge of such wastewater should be solved before scaling-up the results.

Sensitivity analysis and Taguchi application in vacuum membrane distillation

In this work, desalination experiments were performed on vacuum membrane distillation (VMD). Process parameters such as feed flow rate, vacuum degree on permeate side, feed bulk temperature and feed salt concentration were optimized using sensitivity analysis and Taguchi method. The optimum values of process parameters were found to be 2 lpm of feed flow rate, 60 degree Celsius of feed bulk temperature, 5.5 kPa of permeate-side pressure and 5000 ppm of salt concentration. The permeate flux at these conditions was obtained as 26.6 kg/m2⋅hr. The rejection of salt in permeate was found to be 99.7%. The percent contribution of various process parameters using ANOVA results indicated that the most important parameter is feed bulk temperature with its contribution of 95%. The ANOVA results indicate that the percent contribution of permeate pressure gets increased to 5.384% in the range of 2 to 7 kPa as compared to 0.045% in the range of 5.5 to 7 kPa.

Optimization of heavy metal biosorption onto freshwater algae (Chlorella coloniales) using response surface methodology (RSM)

In this study, the interaction of the initial metal concentration, time of reaction and Chlorella coloniales algae dose were taken for the biosorption of Cr, Cd, Co, Fe and As from aqueous solutions using the Box–Behnken design. The regression equation coefficients were calculated and the data confirmed the validity of second-order polynomial equation for the removal of Cr, Cd, Co, Fe and As with Chlorella coloniales algae. Analysis of variance (ANOVA) showed a high coefficient of determination value (R2) for Cr, Cd, Co, Fe, and As, being respectively 0.998, 0.998, 0.995, 0.998 and 0.994. Heavy metal biosorption increased with the increase in time of reaction from 30 h to 100 h then smoothly steadily decreased. The biosorption capacity of Chlorella coloniales increased when initial Cd concentration was increased from 5 to 12 mg/L, and then no change was seen with further increasing in initial Cd concentration. At low concentrations of heavy metal, Chlorella coloniales showed its effectiveness for Cr, Co, Fe and As bioaccumulation, but at high concentrations of heavy metal bioaccumulation efficiency decreased Under optimal value of process parameters, maximum efficiencies for the removal of Cr, Cd, Co, Fe, and As were 97.8, 97.05, 95.15, 98.6 and 96.5% respectively. The results of the present study suggest that use of C. Coloniales algae can be a good alternative to the current expensive methods of removing heavy metals from aqueous solution.

Parametric study of tumbling fluidized bed to evaluate nitrogen release characteristics of biopolymer-coated controlled release urea

ABSTRACTTo impede nitrogen loss due to leaching and NH3 volatilization, pristine urea particles are coated with synthetic polymers such as poly(acrylic acid) and polyethylene for the controlled release of nitrogen. However, due to nonbiodegradability and environmental and economic issues, these synthetic polymers are replaced with cheap, biodegradable, and green coating materials. In this study, borax-modified starch biopolymer is used to produce controlled release urea (CRU) in a tumbling fluidized bed. Central composite rotatable design is used to study the interactive effect of process parameters on time and kinetics of nitrogen release. Nitrogen release in distilled water is monitored by the UV–Vis spectrophotometer and soil burial test is used to observe release in soil. The optimum values of process parameters and response objectives generated by the analysis of variance are validated by triplicates of confirmation runs and the % error is reported as a precision indicator. A mathematical model is used to determine the diffusion coefficient of nitrogen release. Biopolymer-coated urea results in much better release performance when compared with starch-based CRU reported in the literature. The most influential process parameter both for time and kinetics of nitrogen release appears to be the coating time. Release time increases linearly with coating time and the diffusion coefficient decreases with increase in coating time. The kinetic study reveals that some of the samples followed non-Fickian diffusion and others followed Case-II transport during the release of nitrogen.

Indication of the working process of the tractor diesel working on natural gas and alcohols

The article deals with the use of natural gas and alcohol-fuel emulsions as an alternative fuel for tractor diesel. A distinctive feature of the processes of mixture formation and combustion in a diesel operating on natural gas with a burning portion of diesel fuel, and alcohol-fuel emulsions, will be compared with the diesel process heterogeneity of the fuel mixture in terms of cylinder volume, there is a completely different fuel evaporation and no coincidence in time of the processes of formation of fuel-air mixture and its combustion. Consequently, the use of alternative fuels with different chemical composition and local conditions leads to distinctive indicators of the combustion process. Therefore, for the scientific representation of the actual picture of the combustion process of diesel running on natural gas and alcohol-fuel emulsions, the indexing of its working process and a detailed description of the combustion process is carried out. At the same time, for the indexing of the diesel working process, the composition of alternative fuel was used when working on natural gas: gas-80 %, the ignition portion of diesel fuel-20 %; when working on alcohol-fuel emulsions: alcohol (methanol or ethanol) - 25 %, detergent-dispersing additive succinimide C-5A - 0,5 %, water - 7 %, diesel fuel - 67,5 %. As a result of the experimental studies, the dependences of the influence of the 4F 11,0/12,5 diesel modes on natural gas, natural gas with different degrees of exhaust gas recirculation (used to reduce the content of nitrogen oxides in the exhaust gases), methanol and ethanol fuel emulsions on the combustion process were established. The optimal values of the combustion process parameters during the operation of the diesel engine on alternative fuels of these compositions are determined.

Magnetic field assisted finishing process for super-finished Ti alloy implant and its 3D surface characterization

Titanium alloy is used in medical industries due to its biocompatibility. Requirement of implant’s surface roughness and surface topography depends mainly upon its application. In the present study, application of titanium alloy is considered as femoral knee joint implant. The capability of magnetic field assisted finishing (MFAF) process and the polishing tool to provide implant worthy surface is analyzed here. In MFAF process, magnetorheological fluid mixed with abrasive powder in acidic base medium is used as the finishing medium. Characterization of the finished surface is carried out by analyzing 3D surface roughness parameters. The selected 3D surface parameters ( Sa, Spk, Sk and Svk) are considered due to their importance concerning load-bearing articulating surface of knee joint implant. Statistical design of experiment is used for experimental study and subsequently process parameters are optimized. From experimental investigation, the values of Sa, Spk, Sk and Svk are obtained as 11.32 nm, 15.82 nm, 6.51 nm and 41.15 nm, respectively, at optimum process parameter condition. The optimum process parameter values are 901 rpm of the tool, 0.60-mm working gap and 4.30 hrs of finishing time. The obtained values of 3D surface roughness parameters are in the nanometer range and the surface topography will render better wear properties, performance and longer implant life. Further confirmation experiments support the optimized values. The effect of individual process parameter on output responses is also analyzed.

Antagonistic, synergistic and interaction effects of process parameters during oxygen delignification of Melia dubia kraft pulp

Melia dubia is a recently identified hardwood for papermaking. This study reports oxygen delignification of its kraft pulp. Modeling of O2 delignification was done implementing central composite design taking temperature, time and NaOH charge as process parameters while pulp yield, kappa number, intrinsic viscosity and brightness were the process outputs. The high precision quadratic models developed for O2 delignification revealed antagonistic, synergistic and significant interaction effects between temperature, time and NaOH charge. The optimum values of process parameters estimated were 90 °C, 90 min and 1.39% respectively which gave pulp yield 96.64%, total kappa number 10.52, intrinsic viscosity 628.54 cm3/g and brightness 42.52% which were very much comparable to other papermaking raw materials. On the whole, the optimization desirability obtained for O2 delignification was 0.621. The overall O2 delignification efficiency based on the total kappa number and the true lignin kappa number was found to be 30.33% and 38.23% respectively. The O2 delignification practiced in this investigation led to 10.42% increase in brightness and 19.93% reduction in viscosity which would prove advantageous for subsequent elemental and total chlorine free bleaching.

Genetic algorithm approach for optimizing surface roughness of Near dry EDM

In this paper, genetic algorithm (GA) approach is used in order to optimize the surface roughness (Ra) of near dry EDM (ND-EDM) surfaces. Taguchi orthogonal array of L27 is used as design of experiment for the five process parameters viz. pulse on time, duty factor, discharge current, gap voltage and tool rotating speed. ANOVA test was conducted and found that pulse on time was the most significant process parameters with 53.38% of contribution followed by duty factor and discharge current with 20.68% and 20.87% of contribution respectively. A regression mathematical model was developed and determined the relationship between the process parameters and surface roughness. GA approach was employed to optimize the process parameter. Then, a validation test was performed and confirmed the optimal process parameters values.

Optimizing pulsed Nd:YAG laser beam welding process parameters to attain maximum ultimate tensile strength for thin AISI316L sheet using response surface methodology and simulated annealing algorithm

Pulsed laser welding is a powerful technique especially suitable for joining thin sheet metals. In this study, based on experimental data, pulsed laser welding of thin AISI316L austenitic stainless steel sheet has been modeled and optimized. The experimental data required for modeling are gathered as per Central Composite Design matrix in Response Surface Methodology (RSM) with full replication of 31 runs. Ultimate Tensile Strength (UTS) is considered as the main quality measure in laser welding. Furthermore, the important process parameters including peak power, pulse duration, pulse frequency and welding speed are selected as input process parameters. The relation between input parameters and the output response is established via full quadratic response surface regression with confidence level of 95%. The adequacy of the regression model was verified using Analysis of Variance technique results. The main effects of each factor and the interactions effects with other factors were analyzed graphically in contour and surface plot. Next, to maximum joint UTS, the best combinations of parameters levels were specified using RSM. Moreover, the mathematical model is implanted into a Simulated Annealing (SA) optimization algorithm to determine the optimal values of process parameters. The results obtained by both SA and RSM optimization techniques are in good agreement. The optimal parameters settings for peak power of 1800 W, pulse duration of 4.5 ms, frequency of 4.2 Hz and welding speed of 0.5 mm/s would result in a welded joint with 96% of the base metal UTS. Computational results clearly demonstrate that the proposed modeling and optimization procedures perform quite well for pulsed laser welding process.

Development of Mathematical Model for Metal Removal Rate on EDM using Copper & Brass Electrodes

Appropriate selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM). These are the conditions that determine important characteristics such as surface roughness, electrode wear, and material removal rate. In the present work experiments are conducted on EDM using Copper and Brass materials as electrodes and EN8 steel as work material. Discharge current (IP), pulse on time (TON), pulse off time (TOFF) are selected as process parameters and Metal Removal Rate (MR) as response. Factorial design of experiment is used to find the influence of process parameters on response and a mathematical model is developed. Percentage contribution of each factor is determined using ANOVA. Optimum values of process parameters for maximum metal removal rate is obtained using MATLAB program.

EDM machinability and parametric optimisation of 2014Al/Al&lt;SUB align="right"&gt;2O&lt;SUB align="right"&gt;3 composite by RSM

The present work investigates the machinability and influence of process parameters on the machining characteristics in EDM of AA2014/Al2O3 composite. The composite was fabricated through stir casting technique. Process parameters considered are current, voltage, pulse on time and wt.% reinforcement for the purpose of optimisation. Machining characteristics viz. MRR, TWR and SR are investigated. Experiments were designed by adopting rotatable centred composite design based on RSM. The machined surface is further analysed by SEM-EDS. Results revealed that MRR, TWR and SR increase with an increase in the current and pulse on time. However, less TWR and good surface finish are obtained at the lower setting of current, pulse on time and optimum setting of voltage and wt.% reinforcement. Performance measures recorded experimentally at optimum values of process parameters, i.e., 12 A current, 60 V voltage, 60 µm pulse on time and 5 wt.% Al2O3/AA2014 reinforcement are 0.1501 g/min MRR, 0.0032 g/min TWR and 9.367 µm SR.

Modeling and experimental investigation of process parameters in WEDM for surface roughness using regression model

The present study focused on the multiple regression modeling and predicting the surface roughness of the Aluminum hybrid composite during the WEDM process. The hybrid MMC was manufactured by process named as stir casting utilizing particulates of Silicon carbide and graphite each in Al6061 combination. The analyses were outlined with Taguchi L27 design matrix. Mathematical relationships between the surface roughness and WEDM cutting parameters (Pulse on time, Pulse off time, current, gap voltage, wire speed and wire tension) have been investigated. The results show that the multiple regression analysis is a successful method for developing a mathematical model to predict the surface roughness. The optimum value of process parameters for the predicted optimum value of surface roughness (1.285) is pulse on time 106 units (Level 1), pulse off time 60 units (Level 3), peak current 90 units (Level 2), gap set voltage 50 units (Level 3), wire speed3 units (Level 1) and wire tension 12 units (Level 3).The optimum results are adopted in validation study and the results based on WEDM process responses can be effectively improved.

EDM machinability and parametric optimisation of 2014Al/Al&lt;SUB align="right"&gt;2O&lt;SUB align="right"&gt;3 composite by RSM

The present work investigates the machinability and influence of process parameters on the machining characteristics in EDM of AA2014/Al2O3 composite. The composite was fabricated through stir casting technique. Process parameters considered are current, voltage, pulse on time and wt.% reinforcement for the purpose of optimisation. Machining characteristics viz. MRR, TWR and SR are investigated. Experiments were designed by adopting rotatable centred composite design based on RSM. The machined surface is further analysed by SEM-EDS. Results revealed that MRR, TWR and SR increase with an increase in the current and pulse on time. However, less TWR and good surface finish are obtained at the lower setting of current, pulse on time and optimum setting of voltage and wt.% reinforcement. Performance measures recorded experimentally at optimum values of process parameters, i.e., 12 A current, 60 V voltage, 60 µm pulse on time and 5 wt.% Al2O3/AA2014 reinforcement are 0.1501 g/min MRR, 0.0032 g/min TWR and 9.367 µm SR.

Development of Sweet Lime (Citrus Limetta Risso) Pomace Integrated Rice-based Extruded Product: Process Optimization

Sweet lime is rich in nutrients, but has high waste index. In the present study, efforts were delineated on development of third generation rice-based snacks integrated with pulse powder and sweet lime pomace through extrusion. Optimization of the extrusion process was done by response surface methodology for achieving the maximum possible expansion ratio, water absorption index, water solubility index, crude fibre, antioxidant capacity, protein content, overall acceptability; and simultaneously minimum bulk density, hardness and in range colour change. The developed snack had excellent nutritional, physical and sensory attributes and depicted a scintillating prospect for commercial development. The optimum values of process parameters, using RSM were: 70 % rice proportion (along with 15 % pulse powder and 15 % sweet lime pomace powder) with 12 % feed moisture content, 300 rpm screw speed and 137°C die temperature. The overall desirability was 0.62 for extruded product when optimized by RSM

Multi Response optimization of injection moulding Process parameters to reduce cycle time and warpage

The research paper is approach for multi response optimization of injection moulding process parameters. In this Taguchi and desirability function hybridization approach is used. The experiments are plotted using L27 orthogonal array, which is generated with the help of MINITAB-14 software. The process parameters injection pressure, melt temperature, packing time, packing pressure are optimized by multiple response consideration using cycle time and warpage. With the help of the composite desirability value after the desirability function analysis optimal values of process parameters is obtained. The analysis shows optimized process parameters combination of injection pressure, melt temperature, packing time and packing pressure. Confirmation test is also carried to minimization of error of experiments. Experimental result shows that by this injection moulding machine performance can be improved. Injection moulded product has been made by this approach by using virgin Poly propylene. It is thin walled products for the measurement of warpage and cycle time.

Optimization of CO2 Laser Beam Welding Process Parameters to Attain Maximum Weld Strength in Dissimilar Metals

In this study, influence of CO2 laser beam welding (LBW) process parameters such as laser power (P), welding speed (S), focal distance (F) on dissimilar metals of low carbon steel (AISI 1018) and austenitic stainless steel (AISI 316) was examined by using central composite design (CCD) based response surface methodology (RSM). Experimental investigations were performed on 4 kW CO2 laser (TRUMPF TLC1005) with the laser beam spot diameter of 0.15mm and a focal length of 15-25mm. Analysis of variance (ANOVA) was used to analyze the interaction effect of different parameters on the maximum weld strength. A ratification experiment was also carried out in order to validate the optimal process parameters values. Based on the investigation, the maximum weld strength of 458.21 N/mm2 was observed for dissimilar metal butt joint with the optimized laser power of 2600W, the focal distance of 25 mm and a welding speed of 1.5 m/min. Microstructure studies revealed cellular austenite in the form of dendrite and columnar type features accredited to the higher cooling rates concerned with laser welding process. Energy dispersive X-ray analysis (EDX) is carried out to measure the nature of the chemical element distribution in the weld interface. Microhardness tests showed that the maximum hardness was produced in weldment 151-458 Hv and fusion boundary of austenitic stainless steel 193-434 Hv, fusion boundary of low carbon steel 156-468 Hv.