Taguchi Design Research Articles

Monolayer Adsorption of Ciprofloxacin on Magnetic Inulin/Mg-Zn-Al Layered Double Hydroxide: Advanced Interpretation of the Adsorption Process.

In this study, magnetic inulin/Mg-Zn-Al layered double hydroxide (MILDH) was synthesized for the adsorption of ciprofloxacin. The application of various analytical techniques confirmed the successful formation of MILDH. For the optimization of controllable factors, Taguchi design was applied and optimum values were obtained as equilibrium time─100 min, adsorbent dose─20 mg, and ciprofloxacin concentration─30 mg/L. The highest capacity of the material was recorded as 196.19 mg/g at 298 K. Langmuir model (R2 = 0.9669-0.9832) fitted best as compared to the Freundlich model (R2 = 0.9588-0.9657), concluded the monolayer adsorption of ciprofloxacin on MILDH. Statistical physics model M 2 was found to fit best to measured data (R2 = 0.9982-0.9989), indicating that the binding of ciprofloxacin took place on two types of receptor sites (n1 and n2). The multidocking mechanism with horizontal position was suggested on the first receptor site (n1 < 1), while multimolecular adsorption of ciprofloxacin lying vertically on the second receptor site (n2 > 1) at all temperatures. The adsorption energies (E1 = 22.79-27.20 kJ/mol; E2 = 18.00-19.46 kJ/mol) illustrated that the adsorption of ciprofloxacin onto MILDH occurred through physical forces. Best fitting of the fractal-like pseudo-first-order kinetic model (R2 = 0.9982-0.9992) indicated that the adsorption of ciprofloxacin happened on the MILDH surface having different energies. X-ray photoelectron spectroscopy analysis further confirmed the adsorption mechanism of ciprofloxacin onto MILDH.

A Comparative Study on Dip Coating and Corrosion Behavior of Ti-13Zr-13Nb and Commercially Pure Titanium Alloys Coated with YSZ by Taguchi Design

This work evaluates experimentally the corrosion and tip testing of Ti-13Zr-13Nb joint implant alloys and commercially pure titanium (cp-Ti) covered with YSZ nanoceramic. Through the use of the Taguchi design of experiments (DOE) approach, the dip coating process produced a thin sticky covering. The effects of temperature, YSZ concentration, duration, and the level of Ti alloy substrate grinding during dip coating were investigated using a L9-type orthogonal Taguchi array to determine the deposition yield. The thickness and adhesion tests that were utilized to optimize the dip coating conditions served as the input data, and the Ti alloys were coated using the ideal dip coating technique parameters as previously mentioned. For commercial Ti, the ideal values for YSZ coating thickness and adhesion were 60°C, 10 seconds, 10% concentration, and 250 degrees of grinding; correspondingly, for Ti-13Zr-13Nb, the ideal values were 60°C, 10 seconds, 15% concentration, and 400 degrees of grinding. For both Cp-Ti and Ti-13Zr-13Nb, the obtained thickness and removal area (adhesion) were 58.5µm and 11.45%, respectively, and 69.5µm and 9.33%, respectively. High-resolution scanning electron microscopy (FE-SEM) images were used to study the coated alloys; optical microscopy and AFM were used to identify the microstructure and thickness measurements of the coated surfaces; EDAX was used to analyze the coating composition; and XRD was used to analyze the formed phases. The optimized coated Ti alloys' corrosion resistance was investigated in simulated body fluid (SBF) using electrochemical methods such as cyclic polarization and Tafel polarization, and the adhesion strength of the coatings was measured using a tip tester. The following corrosion-resistant values were used to compare Ti-13Zr-13Nb and coated Cp-Ti: In Ringer's solution at 37°C, both coating alloys—Cp-Ti and Ti-13Zr-13Nb—improved corrosion resistance; however, the coated Ti-13Zr-13Nb alloy demonstrated greater corrosion resistance than the coated Cp-Ti alloy (5.417×10-3 and 1.042×10-2, respectively).

Study of thinning rate in incremental forming with hydraulic pressure supports based on taguchi design

Study of thinning rate in incremental forming with hydraulic pressure supports based on taguchi design

Examining the impact of slide burnishing parameters on the 3D surface features of medium carbon steel

Burnishing is a non-cutting finishing technique in which pressure is applied to plastically deform the irregularly distributed surface materials. In this process, the peaks of the surface are pressed into the valleys with a hard tool, resulting in a smoother surface with improved properties. The influence of brunishing parameters such as brunishing force, feed rate and number of passes on the 3D surface roughness of medium carbon steel was analyzed. An orthogonal L9 array Taguchi design was used to create a robust experiment. A CNC milling machine and a confocal microscope were used to grind and measure the workpiece surface. The topography roughness responses Sq, Sv, Sz and Sa were used to evaluate the roughness changes. The optimal parameters for brunishing were a feed rate of 0.05 m/min, 2 passes and a force of 80N for Sq and Sa and a force of 100N for Sv and Sz. This research is expected to provide insights into optimizing mass finishing processes to improve surface integrity, contributing to advances in manufacturing and materials science.

OPTIMIZATION OF α-AMYLASE SYNTHESIS BY BACILLUS VELEZENSIS USING TAGUCHI EXPERIMENTAL DESIGN

This research employs the Taguchi experimental design to optimize the production of α-amylase, a versatile enzyme with diverse industrial applications, using Bacillus velezensis. Thirteen key parameters, including pH, temperature, agitation, inoculum size, aeration and various carbon and nitrogen sources, were systematically investigated using the Taguchi L27 (313) orthogonal array. Initial screening of six seed media formulations identified SM6 (0.5% peptone, 0.5% yeast extract, 0.1% K2 HPO4 ) as the optimal medium, producing 2.8 U mL-1 of α-amylase. Further optimization under the Taguchi framework yielded a maximum α-amylase activity of 1097.31 U mL-1 and total protein of 1230 mg mL-1 at pH 5, 34°C, 4% moong husk as carbon source, and 2% soybean cake as nitrogen source. Two-factor interaction analysis revealed that a temperature of 34°C with 2% soybean cake, and 4% moong husk with 2% soybean cake, provided the best results. Validation experiments confirmed a 31.2% enhancement in α-amylase production under the optimized conditions. This study highlights the efficacy of the Taguchi design in systematically optimizing complex bioprocesses, paving the way for improved α-amylase synthesis with B. velezensis.

Enhancing optimization and reducing machining time of freeform shapes through modeling, simulation, and Taguchi design of experiments with artificial neural networks

Enhancing optimization and reducing machining time of freeform shapes through modeling, simulation, and Taguchi design of experiments with artificial neural networks

Multi-functional Inconel 625 micro-machining and process optimization using ANFIS

The primary objective of this study is to develop an adaptive neuro-fuzzy inference-based system (ANFIS) that assesses the ideal parameters and impact of the micro-electro-discharge machining (Micro-EDM) technique on surface roughness (SR). In this work multi-functional Inconel alloy specimens were machined using micro-elector-discharge machining (Micro-EDM) with zinc-coated copper electrodes in a graphite nano abrasive submersion medium. An ANFIS and Taguchi design of experiments (DOE) was employed to evaluate the Micro-EDM method. The study utilized Taguchi's L9 mixed orthogonal arrays (OA) to consider three process variables, namely open voltage (V), capacitance (C), and powder concentration (CP). ANOVA analysis was conducted to identify important process variables and evaluate their influence on surface properties. The experimental results showed that all approaches were effective in representing the process. Based on the results of the response surface methodology (RSM) and ANFIS predictions, the correlation coefficients (R2) of the experimental roughness were 0.995649 and the root mean square error (RMSE) value was 1.01226e-06, respectively. The results obtained indicate a strong alignment between the predicted and experimental values, effectively fulfilling the proposed objective. These findings hold significant potential for practical applications in the Micro-EDM industry, particularly in the machining of Inconel alloy.

Predictive Modelling and Optimization of the Mechanical Properties of Laser-Coated NB/SiC/Ni Welds Using an ANFIS

In the present work, predictive modelling and optimization with the adaptive network based fuzzy inference system (ANFIS) modelling of the mechanical properties of laser-coated NB/SiC/Ni welds was studied based on the Taguchi design by laser cladding. An ANFIS model based on a Sugeno type fuzzy inference system was developed for predicting the hardness properties of SiC/BN/Ni welds by laser cladding with experimental data required for network training and prediction. Based on analysis of variance, three important factors were taken as inputs for the fuzzy logic inferences, while the hardness properties were taken as the output of the ANFIS. The microstructure of welds was analysed using scanning electron microscopy with an energy-dispersive X-Ray spectrometer. Highly developed leaf-like dendrites and eutectic crystals were found in some areas of the melting zone for the BN/SiC/Ni weld, which was significantly hardened. The ANFIS model based on Taguchi’s design provides a better pattern of response because the predicted and experimental values were highly similar. As a result, a satisfactory result was achieved between the predicted and experimental values of hardness in laser-coated NB/SiC/Ni welds, whereby the success and validity of the method was verified.

A Study on Powder Spreading Quality in Powder Bed Fusion Processes Using Discrete Element Method Simulation

Powder deposition is a very important aspect of PBF-based additive manufacturing processes. Discrete Element Method (DEM) is commonly utilized by researchers to examine the physically complex aspects of powder-spreading methods. This work focuses on vibration-assisted doctor blade powder recoating. The aim of this work is to use experiment-verified DEM simulations in combination with Taguchi Design of Experiments (DoE) to identify optimum spreading parameters based on robust layer quality criteria. The verification of the used powder model is performed via angle of repose and angle of avalanche simulation–experiment cross-checking. Then, four criteria, namely layer thickness deviation, surface coverage ratio, surface root-mean-square roughness and true packing density, are defined. It has been proven that the doctor blade’s translational speed plays the most important role in defining the quality of the deposited layer. The true packing density was found to be unaffected by the spreading parameters. The vertical vibration of the doctor blade recoater was found to have a beneficial effect on the quality of the deposited layer. Ultimately, a weighted mean quality criteria analysis is mapped out. Skewness and kurtosis were proven to function as effective indicators of layer quality, showing a linear relation to the weighted means of the defined quality criteria. The specific weights that optimize this linearity were identified.

Production of β-cyclodextrin by immobilized CGTase in packed bed bioreactor through the medium component by employing Taguchi methodology

This study investigates the optimization of submerged culture conditions for the production of extracellular cyclodextrin glucanotransferase (CGTase) enzyme by Bacillus macerans ATCC 8244, employing Taguchi orthogonal array (OA) experimental design methodology. Five critical factors - starch, peptone, temperature, pH, and agitation speed - were examined at two levels using an OA layout of L8 for the experimental design. Analysis revealed a significant enhancement in CGTase yield, with the modified culture conditions resulting in a 21.2% increase from 513.416 U/ml to 622.5 U/ml. The successful application of Taguchi's design methodology underscores its efficacy in optimizing enzyme production processes. This study highlights Taguchi's design potential as a valuable tool for improving CGTase production efficiency while minimizing resource consumption. Additionally, the utilization of a packed bed bioreactor (PBR) facilitated continuous production of β-cyclodextrin (β-CD), demonstrating stability over 10 days with only a slight decrease in productivity. The Km,app value was determined to be 23.4 mg starch/ml, indicating a slight increase.

Adventitious root culture dyeing and optimisation of dyeing parameters using roots of Gynochthodes umbellata (L.) Razafim and B. Bremer

This study offers a new source of natural dye. Taguchi's design of experiments was used to statistically and optimize the dyeing parameters of different fabrics. The results varied with different fabrics and the optimum conditions for cotton were found to be ultrasonication for 5 min, a material-to-liquor ratio of 10 mL dye to 100 mL water, a temperature of 60 ºC, and a pH of 8. For linen, the optimum values were ultra-sonication for 15 min, 15 mL dye to 100 mL water, pH of 8, and temperature of 80 ºC. Optimum combinations for silk were a temperature of 80 ºC, the material-to-liquor ratio of 20 mL of dye extract to 100 mL water, pH of 8, and ultrasonication for 15 min. The results indicated the commercial viability of dyeing fabrics using this procedure.

Multi-objective optimization for electric discharge drilling of waspaloy: A comparative analysis of NSGA-II, MOGA, MOGWO, and MOPSO

This study investigates the impact of pulse-on-time (TON), current (I), pulse-off-time (TOFF), voltage (V), and tool electrode speed (TES) on material removal rate (MRR), average surface roughness (Ra), power consumption (PC) and surface defects for electrical discharge drilling (EDD) of Waspaloy. Based on a Taguchi design with five factors and four levels, experimental trials reveal TOFF, TON, and TOFF as the most influential factors, contributing 50.45%, 34.29%, and 33.09% to MRR, Ra, and PC, respectively. To address conflicting conditions and optimize responses, non-dominated sorting genetic algorithm-II (NSGA-II), multi-objective genetic algorithm (MOGA), multi-objective grey wolf optimizer (MOGWO), and multi-objective particle swarm optimization (MOPSO) are employed. Comparative analysis of 8 optimal solutions provided by four optimization techniques, which exhibit less than 10% errors in confirmatory experiments, has been done, ensuring better prediction accuracy. MOPSO is preferable to the rest of the optimization techniques due to its lower percentage error. NSGA-II, MOGA, MOGWO, and MOPSO exhibit relative improvement in responses based on confirmatory experiments, establishing them as effective tools for exploring EDD applications. Higher current is confirmed as a primary contributor to increased surface damage through microscopic image analysis, and EDX analysis exposes carbon deposition migration on both the tool and workpiece.

Optimization of hardness values via Taguchi method for chestnut wood etched or impregnated with sodium bicarbonate after artificial aging

In today’s wood industry, research is being conducted to increase material strength, ensure long-term use, and increase its hardness against many harmful external factors. With the studies on the protection of wood, new protection materials and methods are introduced. In this study, wood was etched with solid sodium bicarbonate (NaHCO3) and 1, 2, and 3 bars of air pressure after treatment with NaHCO3 solution and drying. The change in hardness values of impregnated and surface-treated (paint, varnish) chestnut wood after artificial aging was examined. Etching, impregnation, and surface treatment factors were optimized using the Taguchi design of experiments (DoE) after artificial aging for 3, 6, and 9 months. L16 orthogonal array was used to determine the optimum conditions for determining hardness values and their percentage changes. The results showed that the abrasive factor prevails over the effect of surface treatments. It has been understood that the most effective factor in the hardness value changes during the artificial aging period (3-6-9 months) is abrasion, and the factor with the least effect is the surface parameter. The percentage accuracy of the model used in estimating the wear factor average R2 across all dependent variables was 95%.

Recovery of residual polyamide (PA12) from polymer powder bed fusion additive manufacturing process through a binder jetting process

PurposeThis study aims to propose the reuse of PA12 (powder) in another AM process, binder jettiinng, which is less sensitive to the chemical and mechanical degradation of the powder after multiple cycles in the laser system.Design/methodology/approachThe experimental process for evaluating the reuse of SLS powders in a subsequent binder jetting process consists of four phases: powder characterization, bonding analysis, mixture testing and mixture characteristics. Analyses were carried out using techniques such as Fourier Transform Infrared Spectroscopy, scanning electron microscopy, thermogravimetric analysis and stress–strain tests for tension and compression. The surface roughness, color, hardness and density of the new mixture were also determined to find physical characteristics. A Taguchi design L8 was used to search for a mixture with the best mechanical strength.FindingsThe results indicated that the integration of waste powder PA12 with calcium sulfate hemihydrate (CSH) generates appropriate particle distribution with rounded particles of PA12 that improve powder flowability. The micropores observed with less than 60 µm, facilitated binder and infiltrant penetration on 3D parts. The 60/40 (CSH-PA12) mixture with epoxy resin postprocessing was found to be the best-bonded mixture in mechanical testing, rugosity and hardness results. The new CSH-PA12 mixture resulted lighter and stronger than the CSH powder commonly used in binder jetting technology.Originality/valueThis study adds value to the polymer powder bed fusion process by using its waste in a circular process. The novel reuse of PA12 waste in an established process was achieved in an accessible and economical manner.

Optimizing the Composition of Basalt and Heat Treatment of Fly Ash-Based Mullite Ceramics Using the Taguchi Method

The development of industrial activities has an impact on the increase in waste produced, and fly ash, aluminum dross, and basalt dust are no exception. This research studies the potential of these three materials as ceramic materials. Basalt dust from East Lampung was used as filler. The effect on the physical and mechanical properties of mullite (3Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;-2SiO&lt;sub&gt;2&lt;/sub&gt;) ceramics was studied. The manufacture of mullite ceramics based on Taguchi design includes fly ash compositions of 40%, 50%, and 60% and basalt content of 0%, 5%, and 10%. sintering temperatures of 600°C, 900°C, and 1,200°C. Taguchi and Anova were used to determine the effect of independent variables on hardness and density. In addition, macro and microphoto tests were carried out to determine the physical and topographic changes of mullite ceramics. Chemical composition tests with X-ray fluorescence were carried out on raw materials and ceramics that have been formed. Changes in the crystal phase in mullite ceramics were studied through the X-ray diffragment test. XRF test results obtained for raw fly ash (SiO&lt;sub&gt;2&lt;/sub&gt; + Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt; + Fe&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;): 84.84 wt%. The composition of raw basalt is predominantly 48.42% SiO&lt;sub&gt;2&lt;/sub&gt;, 18.82% Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;, 12.60% Fe&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;, and raw aluminum dross with 67.821% Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt; content. The mullite ceramic specimen consists of 38.24–45.30% SiO&lt;sub&gt;2&lt;/sub&gt;, 34.72–48.73% Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;, 6.3–9.99% Fe&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;, and 2.31–5.31% CaO. The crystal phases formed are mullite, pyroxene, and diopside. Analysis of variance shows that hardness is significantly affected by sintering temperature, with a P-value of 0.013 and a contribution of 93.77%. This modeling is acceptable with an error value of 1.26%, or R-sq: 98.74%. The addition of basalt increases the density of mullite ceramics, with a P-value of 0.033 and a contribution of 96.05%. The addition of basalt as a filler is not able to increase the hardness significantly, but it affects the higher ceramic density value. However, the formation of mullite is interesting to study further as a refractory material

Design of Experiments for Optimized Synthesis of Carbon‐Supported Ni Nanoparticles: A Green Chemistry Approach

AbstractMetallic nickel nanoparticles supported on a high specific surface area carbon powder were synthesized by a classical polyol method without external reducing agent or surfactant. Ni/C materials were characterized by TGA, XRD, cyclic and linear voltammetry. To decrease the number of experiments, a Taguchi design of experiments (DoE) was implemented and the effects of different synthesis parameters (nature of the nickel salt, loading of Ni on carbon, nNaOH/nNi ratio and reaction time at reflux) on different responses (crystallite size, electrochemically active surface area and current density for the glucose oxidation reaction at 1.5 V) determined. Optimization of parameter values for decreasing the crystallite size down to 14 nm was achieved using the DoE. For the other responses, strong interactions between parameters avoided straightforward optimization of parameter values. However, some trends could be drawn from the experimental matrix showing that the synthesis of a catalyst loaded with only 10 wt% Ni, with NiCl2 as precursor salt, with a nNaOH/nNi ratio of 6 for 80 minutes at reflux was a good compromise between atom, time and energy savings, costs efficiencies, and electrochemically active surface area and catalytic activity towards the glucose oxidation reaction, particularly in terms of mass activity.

Taguchi Design of Experiments to Optimize Material Removal Rate in Turning AISI 4340 Steel

In this work, an effort is prepared to optimize turning process by maximising the material removal rate (MRR). For experimentation, CNC Spinner 15 lathe machine is used. The input factors are spindle speed, feed rate, depth of cut and type of tool under the 3 altered values of noise factor. Output parameter is MRR. The work piece material is AISI4340 steel. The Taguchi robust design is achieved by implementing spindle vibration as a noise factor. The orthogonal Array L9 is used for experimentation. The MRR is calculated by the defined formula. The data analysis is done by Taguchi technique. The Higher-the-better signal-noise ratio is adopted to compute the quality characteristics S by N fraction of MRR for every run of experiment. Response table is then computed. The main effect plot is the base to discover the best situation of the response parameter. ANOVA is used to guess the significant parameters. The best setting is A-1 B-2 C-2 D-3 and E-3) i.e. spindle speed 780rpm, feed rate = 2.42 mm/rev, coated CVD tool, nose radius=1.2 mm whereas depth of cut = 1.5 mm.

Quenching Process Optimization of Leaf Springs as Tengkuit Material using the Taguchi Method Approach

Tengkuit is a traditional tool used by farmers to care for katuk, chilies, lumai, and others. The problem that farmers complain about is frequent wear and tear and chipping, which according to farmers and craftsmen must maximize quality and this must increase production costs and farmers' expenses. As time goes by, innovations have been made by humans to increase the durability of an object or material by increasing its hardness to save or reduce production costs. This research used qualitative approach with the taguchi method. The Taguchi method is a new engineering technique that aims to improve product and process quality while minimizing costs and resources. Taguchi's experimental design is more efficient because it allows searches involving many factors and numbers, and has good large-scale violent response. The maximum check value is the optimal parameter value for the tengkuit making process. Temperature and cooling media are very influential factors in testing hardness for making tengkuit. The results of the hardness research were shown as the lowest hardness value at a temperature of 600°C, with well water cooling media with a value of 24.3 HRC, and the highest hardness value at a temperature of 800°C. with bromus oil cooling media at a temperature of 700 ° C and a hardness value of 42.9HRC.

Orthogonal array and artificial neural network approach for sustainable cutting optimization machining of 17-4 PH steel under CNC wet turning operations

Sustainable manufacturing strives to increase output while minimizing resource usage, costs, and environmental impact. Tool longevity is crucial, considering material, power, and resource consumption. Challenges like chip removal, heat, and friction necessitate effective solutions. Cutting fluids, like rice bran oil, reduce temperatures, friction, and enhance tool life and surface quality. Research focuses on using rice bran oil with a TiAlN tipped tool to minimize friction and cutting forces. Taguchi's robust design and L-9 orthogonal array reduce experimental trials. Controllable factors include speed, feed, depth of cut, and rice bran oil flow rate, with surface roughness as the performance metric. Taguchi analysis improves turning performance, particularly with 17-4 PH stainless steel. Rice bran oil reduces frictional forces, enabling improved surface quality across all samples, promoting sustainability. Surface roughness (Ra) is notably influenced by feed rate and rice bran oil, contributing 58.06% and 49.5%, respectively. This research underscores the potential of optimizing cutting fluid and process parameters to enhance sustainability in manufacturing.

Investigation into the Impact of Groove Shape on the Tensile Strength of Commercial Steel

In the industrial landscape, welding holds a prominent position, with a significant demand for both effective and high-quality welding processes. Manufacturers, striving to maintain competitiveness, rely on their manufacturing engineers and production personnel to swiftly and efficiently establish manufacturing processes for new products. Among the various welding methods employed, Gas Metal Arc Welding (GMAW) stands out as one of the most widely utilized processes. Several input factors, including welding current, welding voltage, gas flow rate, wire feed speed (WFS), wire size, and welding speed, play a crucial role in determining the quality of welding outcomes. Taguchi's design, recognized for its effectiveness, serves as a powerful optimization tool for enhancing the quality and performance output of manufacturing processes. In this particular study, GMAW was employed to weld commercial steel under predetermined factors of welding voltage, WFS, and groove shape. The X-groove welding exhibited lower tensile strength and hardness compared to V-groove weldments. Utilizing Taguchi's design, the objective was to identify the optimal process factors that would result in higher tensile strength and hardness. The analysis revealed that welding groove shape had the most significant impact on both tensile strength and hardness, followed by voltage. In contrast, WFS exerted the least influence on tensile strength and hardness. The optimized combination of welding factors identified was a V-groove shape, 20 V welding voltage, and a 5.9 m/min WFS.