Process Parameters Research Articles

INTEGRATION OF QFD AND DEA METHODS TOGETHER TO PRIORITISE CUSTOMER EXPECTATIONS: THE CASE OF A SERVICE ORGANISATION

Quality Function Deployment (QFD) is a method used to transform customer expectations into technical requirements and to identify the technical requirements that need to be improved to meet these expectations. QFD stands out as a method that has found wide application in the literature and industry in terms of its advantage in transforming relatively more abstract customer expectations into concrete product and process parameters and its ease of application. One of the most important disadvantages of the method is that in the prioritization of technical requirements related to customer expectations, criteria such as the cost of the technical requirement in question, the implementation time of the necessary improvement activities, etc., are not considered. In this study, an approach in which Data Envelopment Analysis (DEA) methods are applied together with the QFD method to take into account the costs in the prioritization of technical requirements is presented. According to the results of a sample application carried out in a cafe business to test the approach, it is concluded that taking costs into account in the prioritization process should be prioritized in order to meet customer expectations.

Biodegradable hydroxylase polyols production from epoxidized palm oleic acid

Recently, the trend of using renewable sources has great attention in the production of polyol chemicals via the epoxidation method. Palm-based polyols produced from the epoxidation and hydroxylation methods usually have low hydroxyl values (below 200 mg KOH/g). This study aimed to synthesize the hydroxylase polyols with a higher hydroxyl value from the renewable source palm oil. The epoxidized palm oleic acid was synthesized using the in situ performic acid, which is obtained from the reaction of formic acid and hydrogen peroxide. The Taguchi method was executed to optimize the epoxidation process for the maximum production of epoxidized oleic acid. Then, optimized epoxidized palm oleic acid was hydroxylated to produce polyols. In addition, the effect of process parameters on the polyol yields was also studied. At the optimum process parameters, the response of relative conversion to oxirane (RCO) with the determination of oxirane oxygen content (OOC) was found at the maximum value of 82%. According to the results, the maximum hydroxyl value produced was 339 mg KOH/g. A kinetic study revealed that the oxirane cleavage by methanol is a second-order reaction whereas the formation of epoxidized palm oleic acid is a first-order reaction.

Research on wafer-level SiC microgroove array process via integrated molding-etching process

Silicon carbide (SiC) microgroove arrays (MGAs) play a pivotal role as optical components in modern optical engineering. This paper introduces an innovative approach for the fabrication of MGAs on hard materials. This method integrates hot embossing (HE) and inductively coupled plasma (ICP), utilizing polydimethylsiloxane (PDMS) as the intermediary mold due to its excellent demolding performance and shape replication qualities. The process involves transferring the MGAs from the Ni-P master mold to the PDMS mold, followed by replication onto the photoresist surface by hot embossing. Subsequently, the MGAs on the photoresist mask is etched into the hard substrate material using ICP etching. For efficient customization of MGAs, a reliable geometrical model based on angular dependence theory is developed to assist in selecting process parameters and designing masks. The correlation between etching selectivity and characteristic dimension is elucidated. Experimental results demonstrate that the sidewall angle decreases with higher selectivity and increases with a greater sidewall angle on the patterned mask. Plasma etching reveals unaffected areas in convex corners and the forming errors in concave corners, highlighting a high angular dependence of the etch rate. Moreover, minimizing microdefects can be achieved by optimizing process parameters and reducing etch time.

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Study of Parameters Influencing Wrinkles in the Deep Drawing of Fiber-Based Materials Using Automatic Image Detection

The evaluation of wrinkles in deep-drawn fiber-based materials is crucial for the assessment of product quality and the optimization of manufacturing processes. Wrinkling is a common phenomenon in the deep-drawing process and is caused by tangential compressive stresses on the flanges of the blank. This phenomenon is particularly prevalent for fiber-based materials with high tensile depths and can seriously affect the appearance and mechanical properties of the final product. The objective of this study is to identify the key process parameters affecting wrinkling and to deepen the understanding of their roles and interactions using wrinkle data for deep-drawn paper products. Image analysis techniques are employed, supported by a specially constructed darkroom platform to ensure uniform light intensity for capturing photographs. An automated program is developed for the detection and evaluation of wrinkle characteristics and distribution, which allows the free choice of the region to be detected and the representation of the wrinkle geometry not limited by the number. To enhance the precision of this program, the ellipticity is initially rectified for products without flanges, specifically cup-shaped deep-drawn products. The ellipticity is caused by the pronounced springback effect of the paperboard. The approach is employed to investigate the impact of material properties, blank holder force, drawing depth, drawing clearance, and punch speed on wrinkling formation after the deep-drawing process. The findings reveal that the blank holder force and drawing clearance are critical factors in wrinkle formation, with higher blank holder force generally leading to increased wrinkle numbers.

A comparative experimental study on abrasive flow machining vs flow peening GOV processes on Inconel 718

Inconel 718, a nickel-based super alloy, has a broad applications area from aerospace, medical and defence to traditional industries because of its high durability, corrosion resistance and elevated temperature performance. Unconventional surface treatment methods of abrasive flow machining (AFM) and shot peening (SP) are applied to improve the mechanical performance of Inconel 718. In this work, a new surface treatment process known as flow peening (GOV) already developed by combining the advantages of abrasive flow machining (AFM) and shot peening methods such as surface finishing and residual compressive stress generation respectively was applied experimentally for Inconel 718. The effects of process parameters for GOV and AFM processes on the surface quality of the specimens were experimentally investigated. White layer decrease, surface roughness decrease and material removal amount were discussed for both processes. The best surface quality with 0.56 μm Ra surface roughness value and material removal amount of 7.2 mg were obtained by GOV process while similar level of surface roughness value of 0.52 μm was obtained by removing 6648.03 mg material for AFM. When the AFM process was continued, the best values of 0.24 μm Ra was obtained removing excess material of 17,385.60 mg compared to the GOV process. Also, all these results were supported by SEM images.

Characterization and simulation of AlSi10Mg reinforcement structures by direct energy deposition by means of laser beam and powder

Among metal additive manufacturing technologies, direct energy deposition (DED) processes have the advantage to be easily integrable in a manufacturing chain with other conventional technologies. This characteristic can be exploited by designing reinforcement structures to be added by DED onto pre-existing subcomponents to tailor the part’s mechanical properties while keeping the part lightweight. This study focuses on DED by means of laser beam and powder process optimization to improve material quality and geometrical accuracy of AlSi10Mg reinforcement structures while preventing excessive thermal deformations and material dilution into the substrate. These results are compared with finite elements numerical simulations of the deposition process, comprising thermo-elastic deformation and material deposition, to predict the bending and reinforcement of the processed substrate. In particular, the model includes the deterministic prediction of the deposition profile as a function of the process parameters and a few condition-specific coefficients: once calibrated, the model was used to compare the numerical and experimental residual deformation of the reinforced sample, obtaining promising agreement. The reinforcement provided to a 1.5 mm thick substrate by a single wall of deposited materials, with cross-sectional dimensions of 2 mm in width and 2.5 mm in height, was evaluated by three points bending. With the reinforcement on the tensile side of the stresses, the energy absorbed by the material plastic deformation increased by 2.4% as compared to the substrate alone, while with the reinforcement on the compression side of the stresses the energy absorption increased by 75.8% on average.

Wear studies on friction stir processed surface modified AZ61 magnesium alloy with nano titanium oxide

ABSTRACT Surface modification of magnesium alloy enables the improvement of wear characteristics for use in sliding applications and places where surface hardness improvement is essential without affecting the microstructure of the underneath material. In this study, a pin-on disc wear test was used to examine the dry sliding wear behaviour of AZ61 Mg alloy reinforced with nTiO2 by a recursive friction stir processing technique. The trio-behavior of the surface-modified Mg alloy was detailed by the response surface methodology-central composite design matrix with the use of design experiments, considering three levels of reinforcement (%), sliding speed, and axial load parameters. In order to achieve the desired results of minimal wear loss, lower friction coefficient (COF), and lower friction force between surfaces (FF), this present work employed design expert software to develop a generative mathematical model to optimize the process parameters. Wear mechanisms were investigated using images captured by scanning electron microscope.

Optimal process parameter determination in selective laser melting via machine learning-guided sequential quadratic programing

Selective Laser Melting (SLM) is a widely used additive manufacturing method with critical processing parameters such as Laser Power, Scanning Speed, Hatch Distance, and Laser Beam Diameter, which significantly impact process quality and mechanical properties of fabricated parts like Relative Density, Hardness, and Surface Roughness. This study investigates an effective approach to modeling the SLM process for predicting and optimizing processing parameters using a combination of Machine Learning (ML) and Sequential Quadratic Programing (SQP). The proposed method aims to predict the mechanical properties of SLM-produced AlSi10Mg parts using Machine Learning techniques and then transform the process into a constrained multiple-objective optimization model employing the SQP algorithm to determine optimal process parameters. Artificial Neural Networks (ANN), Gaussian Process Regression (GPR), and Support Vector Machine (SVM) algorithms are applied to establish correlations between process parameters and mechanical properties, represented as mathematical functions. A cost function is formulated using these functions and minimized using the SQP method. Statistical analysis is implemented to validate the influence of processing parameters on mechanical properties accordingly. The outcomes of the method are verified through additional experiments and analyses using Micro-CT scanning techniques. The results demonstrate that processing parameters have a significant impact on part properties across different scales, with Micro-CT scanning proving instrumental in validating mechanical properties. Overall, this study establishes that multiple objectives can be efficiently optimized through the integration of ML and SQP methods, complemented by a judicious number of experiments.

Evaluation of referral pathways for coronary artery bypass surgery patients; comparison on clinical outcomes, quality of life and process parameters

Objective To compare clinical outcomes, quality of life and process parameters of coronary artery bypass grafting (CABG) patients treated in a regional hub-and-spokes network. Methods Data from patients who underwent elective CABG from 2016 to 2020 at a Dutch heart center ('hub') were grouped by referral pathways by the cardiologist: internal (A) and four external (B–E). Clinical outcomes, quality of life, and process parameters were evaluated. Results In 690 CABG patients, no significant differences in baseline characteristics and clinical outcomes between care pathways were revealed. Hub-treated patients had shorter median hospital (7 days, IQR 6–8; p<.01) and preoperative stays (1 day, IQR 1–1; p<.01) compared to those treated at spokes. Within 8 weeks, 97.2% had outpatient visits, with pathways A, C, and E attending more frequently than B and D. Time to first visit ranged from 31–44 days. Cardiac rehabilitation began at 6 weeks for 40.4% of patients, with higher rates in Pathways B and D (66.4% and 50.0%) compared to the hub, C, and E (27.2% and 33.7%; p<0.001). Conclusion The study revealed notable variations in process parameters among different care pathways within a hub-and-spoke model for CABG patients, while maintaining comparable clinical outcomes and quality of life.

Optimization of Laser Cladding Process Parameters and Analysis of Organizational Properties of Mixer Liners

Aiming to address the wear and replacement inconvenience of concrete mixer liners, this study utilizes a laser cladding system to clad Fe60 alloy powder on the liner. It investigates the influence of different process parameters on the forming quality of the Fe60 alloy powder cladding layer. The optimal process parameters were obtained by weighted comprehensive evaluation, and single-layer multi-pass cladding experiments were carried out under the optimal process parameters to investigate the effects of a 30%, 40%, and 50% lap rate on the surface flatness and forming quality of the cladding layer. Using a metallographic microscope, a scanning electron microscope analysis of the macro morphology and microstructure of the cladding layer was conducted, a DPT-5 penetration flaw detector was used to observe the cracks on the surface of the multi-channel cladding, a microhardness tester and friction and wear experimental machine were used for the hardness of the cladding layer, and an abrasive wear resistance test was conducted. The results show that under the process parameters of a laser power of 900 W, powder feeding speed of 7 g/min, scanning speed of 600 mm/min, and 50% lap rate, the average microhardness of the fused cladding layer reaches 742 HV, which is 1.8 times higher than that of the liner plate, and the coefficient of friction is 0.57, which improves the liner plate’s wear resistance performance and service life.

Pediatric Orally Disintegrating Tablets (ODTs) with Enhanced Palatability Based on Propranolol HCl Coground with Hydroxypropyl-β-Cyclodextrin

Background: Propranolol, largely prescribed as an antihypertensive and antiarrhythmic drug in pediatrics, is characterized by a bitter taste and an astringent aftertaste. Currently, the therapy requires crushing of tablets for adults and their dispersion in water many times a day, leading to loss of dosing accuracy, low palatability, and poor compliance for both patients and caregivers. Objectives: This work aimed to exploit cyclodextrin complexation by cogrinding to develop orally disintegrating tablets (ODTs) endowed with reliable dosing accuracy, good palatability and safety, ease of swallowability, and ultimately better compliance for both pediatric patients and caregivers. Results: Different formulation variables and process parameters were evaluated in preparing ODTs. The technological and morphological characterization and disintegration tests were performed according to official and alternative tests to select the ODT formulation based on the drug Hydroxypropyl-β-cyclodextrin (HPβCD) coground complex form containing Pearlitol® Flash as the diluent and 8% Explotab® as the superdisintegrant, which demonstrated the highest % drug dissolution in simulated saliva and acceptable in vitro palatability assessed by the electronic tongue, confirming the good taste-masking power of HPβCD towards propranolol. Conclusions: Such a new dosage form of propranolol could represent a valid alternative to the common extemporaneous preparations, overcoming the lack of solid formulations of propranolol intended for pediatric use.

Analysis and Optimization of Super Duplex Stainless Steel Deposition in Wire Arc Additive Manufacturing Using Machine Learning Techniques

&lt;div&gt;This article presents experimental investigations and machine learning-based analysis on depositions of super duplex stainless steel (SDSS ER2594) material in wire arc additive manufacturing (WAAM) considering the process parameters namely voltage, wire feed rate, torch travel speed, and gas flow rate. Deposition efficiency and surface height values of the accumulated material were measured to build machine learning models using artificial neural network (ANN) and adaptive neuro-fuzzy inference system (ANFIS). The developed ANN model could predict the deposition efficiency and surface height with mean absolute deviations (MADs) of 8.9% and 16.1%, respectively. The MAD for prediction of the two responses for ANFIS model was found to be 6.1% and 14.9% as compared to the experimental data. Multi-objective optimization was also performed to obtain optimal solutions to achieve desired deposition results. Mechanical properties and microstructures of the deposited materials with optimal processing parameters were found comparable to that of the base materials.&lt;/div&gt;

Effect of hydrotalcites in tannate conversion coatings for iron artefacts

AbstractThe surface treatment of iron artefacts requires an application of the proper conservation coating to prevent further corrosion deterioration. Tannate coating is preferred as a conservation agent of iron/steel with the desired black appearance of the surface. In this work, the modification of the tannate coating with hydrotalcites to improve conservation ability was studied. Methodology of the surface treatment was developed, and process parameters: hydrotalcite addition, applied layers, immersion time and pH of the stock solution were studied. The treated surface was characterised by various methods e.g. Raman spectroscopy, EDX measurements and electrochemical characterisation, and the quality of the surface treatment was evaluated with respect to cyclic QUV test. Effect of hydrotalcite addition on quality of the conversion coating was confirmed and explained by incorporation of Al in the coating. Mechanism of the modified conversion coating was proposed.

Investigation of Arc Stability in Wire Arc Additive Manufacturing of 2319 Aluminum Alloy

Wire Arc Additive Manufacturing (WAAM) technology, known for its low equipment and material costs, high material utilization, and high production efficiency, has found extensive applications in the fabrication of key components for the aerospace and aviation industries. The stability of the arc is crucial for the WAAM process as it directly affects the forming of the parts. In this study, the monitoring data of electrical signals and arc morphology during the WAAM process of 2319 aluminum alloy were investigated using a high-speed camera system and current/voltage acquisition system. By analyzing the current and voltage signals, as well as the arc imaging results, the influence of arc stability on the forming of the cladding layer was studied. The experimental results indicated that when both current and voltage exhibit regular periodic fluctuations, this manifests as a stable short-circuit droplet transition form, while sudden changes in these signals represent abnormal droplet transition forms. The adaptability of the process directly influenced the arc shape, thereby affecting the forming of the cladding layer. Under the process parameters of welding speed of 240 cm/min and wire feeding speed of 6.5 m/min, it was observed that the current signal exhibited a tight state and the variance of the arc width was minimized. This indicated that at a higher wire feeding speed, the droplet transfer frequency was increased. Under these process parameters, the arc output was more stable, resulting in a uniform metal coating.

Interlayer-free laser coating of AISI H11 tool steel for H11/Cu composite material

Copper-based materials in combination with steels are of great interest for various applications in industry, such as tool manufacture, due to their high thermal conductivity. Additive manufacturing (AM) is beneficial for both tailored part geometry and customized material design. With laser-based AM, the copper-steel interface is highly prone to cracking. This study investigates a strategy of laser coating AISI H11 tool steel for a composite material consisting of AISI H11 tool steel and copper (H11/Cu) without using Ni-based interlayers. As an austenite stabilizing element, Ni dilution in H11 could lead to soft retained austenite, impeding wear resistance. The approach in this work employed presintering of tool steel powder to generate a porous H11 preform. Laser-based directed energy deposition (DED-LB/M) was used for coating H11 tool steel on the porous H11 preform followed by copper infiltration of the preform. The investigation of the effects of the main processing parameters: laser power, feed rate, and powder mass flow on the weld track geometry, clearly revealed different mechanisms when coating the porous preform compared to the conventional substrate. Defects at the coating/substrate interface such as cold crack formation were successfully avoided by adjusting the process parameters and process sequence. The developed processing strategy may in the future combine material extrusion of metals (MEX/M) and DED-LB/M to allow for intricate preform geometries and to generate H11 coatings on H11/Cu, respectively.

Impact of molecular architecture and draw ratio on enhancement of targeted mechanical properties of machine direction oriented polyethylene films produced after blown film extrusion

Conventional multi-material multi-layer flexible packaging offers excellent properties. However, it has recycling challenges, necessitating a shift to mono-material multi-layer flexible packaging for example all-polyethylene (PE) packaging which can be tailored through various synthesis and processing methods for different layers. In this work, we study how the key molecular properties (number-average molecular weight ( Mn), weight-average molecular weight ( M w), molecular weight distribution (MWD), comonomer content (short chain branching)) and machine direction orientation (MDO) process draw ratio (MDX) influence the final morphology and mechanical properties of MDO-PE films which are intended as the outer layer of mono-material all-polyethylene multi-layer flexible packaging. Five PE grades and various blends were extruded and blown into films. Selected blown films were machine direction oriented to obtain the final MDO-PE films. Furthermore, one selected PE blown film was processed at different MDO process draw ratios while keeping other process parameters constant. From the molecular properties point of view, the higher molecular weight fractions provide a higher possibility for uniform stretching whereas lower molecular weight fractions provide a higher natural draw ratio and therefore higher modulus and stiffness enhancement. Further, the results show that increasing MDO process draw ratio leads to more fibrillation and increased crystallinity. Consequently, the tensile modulus and stiffness at the higher draw ratios increase as well and are comparable to conventionally used polymers in outer layers of multilayer flexible packaging. Thus, this work demonstrates that MDO-PE films with enhanced modulus can provide sufficient stiffness for the design of outer layer of mono-material multi-layer all-PE packaging which presents higher potential for mechanical recyclability.

A comprehensive validation of GRA with ant colony optimization for robust optimal design: A case study on the forming process

Sheet metal forming design involves numerous factors and controlling all these parameters to prevent cracks is a major challenge to maintain the quality. Therefore, the careful selection of process parameters is critical for ensuring product longevity. Several researchers employed different techniques for optimal selection of process parameters but consistency among the techniques and validation of results in real time scenarios will play a pivotal role in determining the suitable parameters. Therefore, the current work presents a validation method of Grey Relational Analysis (GRA) results with Ant Colony Optimization (ACO) for the robust optimum design with an illustrative example of forming process. Al 6061 – T6 alloy was chosen as a material for deep drawing process and L27 Orthogonal Array was planned to conduct experiments with four input parameters such as blank thickness, Die and Blank Temperature, Die Speed, Lubrication at three levels each. Punch force and Thickness variation were considered as the output parameters. GRA Technique was implemented to find the best optimal combination and regression equation was developed to predict the nature of objective function. These results were given as an input to ACO, a nature inspired algorithm to search for the optimal solution with in the design space. Sensitivity analysis has also been performed to highlight the effectiveness of the proposed solution in terms of solution quality and computational efficiency. The ACO method, GRA technique and the experimental results are almost similar with a margin of acceptable deviation. The results indicated the robustness of the projected approach in achieving the quality of solution.

Optimization of manufacturing process for serotype 14 pneumococcal capsular polysaccharide

Streptococcus pneumoniae is a pathogenic bacterium that causes infections such as pneumonia, meningitis, otitis media, and bacteremia. The prevention of pneumococcal disease by vaccination has become more urgent due to increased antibiotic resistance. Pneumococcal capsular polysaccharides (CPS) are effective vaccine antigens that stimulate the host to produce protective antibodies. S. pneumoniae serotype 14 is one of most prevalent types in Latin America and across the world. However, the yield of S. pneumoniae serotype 14 CPS from existing fermentation processes remains low and requires improvement. In this study, various aspects of the fermentation process were optimized to improve pneumococcal growth and polysaccharide productivity, including feed medium, cultivation gas environment, fermentation pH, and temperature. A simplified purification method was also developed to obtain pure CPS, including ultrafiltration, acid and ethanol precipitation, diafiltration, and lyophilization. These fermentation optimizations significantly enhanced the optical density of pneumococcal bacterial cultures and increased fermentation yields to 2.4–2.6 g/L—significantly higher than previously achieved. Furthermore, the test results of pure CPS could meet the requirements in the European Pharmacopoeia (11th edition). These optimizations provide valuable insights into the nutritional requirements and impact of varying fermentation process parameters on pneumococcal growth and CPS productivity, thus contributing to the development of a more efficient and cost-effective method for the production of pneumococcal CPS—essential for manufacturing vaccines against pneumococcal infections.

Evaluation of Tensile Strength of Dissimilar Metals SS 316-pure Zn Joining by Friction Welding Method

Welding of dissimilar metals has always been a challenge in industrial applications. In this study, the joining of SS 316 and 99.9% pure zinc by continuous drive friction welding has been carried out. The welding process is carried out with parameters such as rotation speed, friction pressure, forging pressure, and burn length being kept constant for all weld joint samples. This friction time is selected through the process parameter approach carried out on aluminium alloy material. The experimental results were analysed by tensile test and microstructure using a scanning electron microscope (SEM) to characterise the microstructure. Tensile test results from friction welding with variations in friction time from 30 to 80 seconds obtained a higher tensile strength of the joint in the 30 to 50 seconds friction time range. In this experiment, the maximum joint tensile strength is obtained at 53.93 MPa, and the maximum modulus elasticity of 128.60 GPa at 35 seconds of friction. Solid-state welding makes it possible to join SS 316 and pure zinc, which is difficult to join in conventional fusion welding methods.