Taguchi Method Research Articles

Optimization of Forming Process Parameters for Automotive Advanced High Strength Steel Parts Using the Taguchi Method

Optimization of Forming Process Parameters for Automotive Advanced High Strength Steel Parts Using the Taguchi Method

Analysis of Output Performance of Airflow Energy Harvester Using Diamagnetic Levitation Based on Taguchi Method

Analysis of Output Performance of Airflow Energy Harvester Using Diamagnetic Levitation Based on Taguchi Method

Study on the influence of material hardness on the performance of V-shaped non-pneumatic tyres

Material selection is a crucial factor in the design of non-pneumatic tyres (NPT). Most NPTs are integrally manufactured using polyurethane materials for the supports, the inner ring, and the outer ring. It is evident that designing different components with varying material hardness will have distinct impacts on NPT performance. To study the influence of material hardness on the performance of V-shaped non-pneumatic tyres (VS-NPT), we developed finite element models of VS-NPTs with different TPU materials. To validate the finite element models, we manufactured tyres with three different hardness levels and conducted performance tests. Based on this model, a design concept is proposed where different components use materials with varying hardness levels. To elucidate how material hardness affects VS-NPT performance, the Taguchi method was used for analysis. The results reveal that increased material hardness leads to higher triaxial forces and triaxial stiffness in integrally designed VS-NPTs. Regardless of variations in the structural parameters of existing VS-NPTs, the spoke material has a significant impact on triaxial stiffness and contact area. When the spoke thickness exceeds 7.3 mm, the tread material predominantly affects the contact area.

An investigation into the surface integrity and cutting force characteristics in titanium alloy end milling using soluble oil and MQL as coolants

Ti–6Al–4V, a titanium alloy, is a lightweight material characterized by a relatively high strength-to-weight ratio. Due to its exceptional resistance to corrosion, this material is extensively used in the aerospace and automotive sectors. Additionally, its biocompatibility has enabled its use in the medical field. An inherent difficulty in end milling titanium alloy is its modest thermal conductivity and covalent reactivity with other compounds. The low thermal conductivity of the alloy results in elevated tool temperatures, which expedites tool wear and diminishes tool longevity. To address these issues, end milling is performed using lubricants such as minimum quantity lubrication (MQL) and soluble oil. A variety of cutting speed, feed, and depths of cut were employed during the end milling process to analyze their influence on surface integrity and tool life. Optimization of the cutting parameters was achieved using ANOVA and Taguchi methods. The cutting speed influenced the cutting force in both soluble oil and MQL as coolants. Minor tool burning was observed when using soluble oil, whereas this issue was not encountered with MQL. Additionally, MQL demonstrated a faster heat removal rate compared to soluble oil during the milling process.

Optimization of material properties and performance of flexible thermoelectric generators with/without graphene

With the advancement of energy harvesting methods, the power level consumed by electronic circuits and sensors has been reduced so that self-sufficiency in power can be achieved, and the use of flexible thermoelectric generators to supply electrical energy is one of these methods. In this study, the manufacture of flexible thermoelectric generators is successfully developed and verified using a numerical method. The process follows the sandwich method of the conventional thermoelectric module and utilizes two different elastomers (polydimethylsiloxane and Eco-Flex) and thin copper sheets. Among the nine cases designed by the Taguchi method, the maximum tensile strength of the elastomer is 0.967 MPa, stemming from the operation conditions of 6 min stirring time, 85 °C heating temperature, and 3 h heating time. This strength is substantially higher than those of the other eight cases. The open-circuit voltage of the manufactured flexible thermoelectric generator with an internal resistance of 1.5 Ω is 0.011 V. The output power under a temperature difference of 75 °C is 11 μW. After blending graphene into polydimethylsiloxane, the elastomer’s thermal conductivity at 370 K rises by 9.6 folds. This results in the output power being lifted to 0.0515 W (75 °C temperature difference), accounting for an amplification of 4,681 times. Numerical simulations are also performed to aid in figuring out the detailed performance of the flexible thermoelectric generator. The errors between numerical simulations and experiments are between 4.6 % and 5.2 %, showing the reliability of the numerical predictions. The fabricated flexible thermoelectric generators can be practically used for green power generation by harvesting industrial low-temperature waste heat and biothermal energy, potentially driving sensors on industrial devices, the human body, and animals.

Optimizing Injection Molding for Propellers with Soft Computing, Fuzzy Evaluation, and Taguchi Method

This research explores multi-objective optimization in injection molding with a focus on identifying the optimal configuration for the moldability index in aviation propeller manufacturing. The study employs the Taguchi method and fuzzy analytic hierarchy process (FAHP) combined with the Technique for the Order Performance by Similarity to the Ideal Solution (TOPSIS) to systematically evaluate diverse objectives. The investigation specifically addresses two prevalent defects—shrinkage rate and sink mark—that impact the final quality of injection-molded components. Polypropylene is chosen as the injection material, and critical process parameters encompass melt temperature, mold temperature, filling time, cooling time, and pressure holding time. The Taguchi L25 orthogonal array is selected, considering the number of levels and parameters, and Finite Element Analysis (FEA) is applied to enhance precision in results. To validate both simulation outcomes and the proposed optimization methodology, Artificial Neural Network (ANN) analysis is conducted for the chosen component. The Fuzzy-TOPSIS method, in conjunction with ANN, is employed to ascertain the optimal levels of the selected parameters. The margin of error between the chosen optimization methods is found to be less than one percent, underscoring their suitability for injection molding optimization. The efficacy of the selected optimization method has been corroborated in prior research. Ultimately, employing the fuzzy-TOPSIS optimization method yields a minimum shrinkage value of 16.34% and a sink mark value of 0.0516 mm. Similarly, utilizing the ANN optimization method results in minimum values of 16.42% for shrinkage and 0.0519 mm for the sink mark. Doi: 10.28991/ESJ-2024-08-05-025 Full Text: PDF

Optimization of biodiesel blend on single cylinder diesel engine using Taguchi method

Optimization of biodiesel blend on single cylinder diesel engine using Taguchi method

An experimental analysis of mechanical properties for a dissimilar pattern structure in the 3-D printing of a PLA5F filament using the Taguchi method

Abstract Many automobile components and machine parts can be fabricated using the Fused Deposition Modeling (FDM) process with materials such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PET-G), and polymeric composite materials (e.g., PLA with carbon fiber, PLA with glass fiber). In this study, a new polymeric composite material was fabricated using Polylactic Acid and natural flax fiber was analysed for tensile stress, elongation, and impact load resistance using Taguchi Analysis. This analysis optimized the printing parameters, including layer thickness (0.15, 0.25, 0.35 mm), nozzle movement speed (80, 100, 120 mm s−1), filling structure (Lines - a, Triangular - b, and Octet - c), and occupancy rate (20%, 40%, 60%). The American Society for Testing and Materials (ASTM) standards for tensile strength (ASTM D638) and impact strength (ASTM D256) were used for evaluation. As a result, layer thickness was found to be the most effective variable for improving tensile characteristics, compared to extruder temperature, occupancy rate, or filling structure pattern. Mechanical properties including a layer thickness of 0.25 mm, an occupancy ratio of 20% for the bottom of the 2nd layer and 40% for the top of the 4th layer, triangular and octet filling structures, a nozzle speed of 100 mm s−1, and an extruder temperature of 200 °C are considered the most appropriate parameters for producing automotive parts in Three Dimensional (3D) Printing. Due to its tensile properties and impact strength resistance, these settings can be utilized in potential application in a wide variety of machine parts and vehicle components.

3D FEM forming simulation optimization and experiment on bevel thread-forming screw

Abstract This study adopts 3 forming passes and 1 thread rolling process as the multi-pass schedule of bevel thread-forming screw. The finite element simulation software is used to simulate the plastic behaviour of forming and thread rolling processes. The geometry shapes, the part dimensions of each pass, the effective stress, the effective strain, the forming force and the die stress of each pass can be reached via FEM simulation. Moreover, especially Taguchi method for the maximum force pass is conducted to optimize the forming processes. Considering 4 control factors such as A: head arc radius (rH), B: flange thickness (t), C: corner radius (r), and D: frictional factor(m) and 3 levels to establish the orthogonal array table for optimum forming force, the influence rank and the optimal parameters combination are obtained to carry out the realistic experiment for confirming the feasibility of FEM simulation optimization. In a word, the influence rank of control factors: flange thickness (t) > head arc radius (rH) > corner radius (r) > frictional factor (m), and the optimal parameters combination is A3B3C3D1 (rH=42 mm, t=1.3 mm, r=0.7 mm, and m=0.12).

Optimization study of proton exchange membrane fuel cell parameters based on Taguchi method for central spiral flow field

Optimization study of proton exchange membrane fuel cell parameters based on Taguchi method for central spiral flow field

Comparative studies of Taguchi dynamic analysis, statistical, and artificial neural networks for low-carbon steel corrosion inhibition in acidic media

The aim of the present work is to optimize the corrosion inhibition process of low-carbon steel in 2.5 M phosphoric acid at different temperatures and inhibitor concentrations. The weight loss method is used to evaluate the corrosion rate in the absence or presence of a corrosion inhibitor. Taguchi dynamic (L16), mathematical regression, and artificial neural networks (ANN) are used during the data processing. The outcomes showed that the %IE increased with inhibitor concentration and temperature up to 50 °C. The Taguchi method showed that the optimum conditions for the corrosion inhibition temperature were found to be 50 °C and a 0.05 M KI concentration. Two mathematical models are proposed to construct a relationship between %IE and independent variables: the exponent model (EM) and the polynomial model (PM). PM was more accurate than EM, with a significant correlation coefficient approaching 0.9851. Temperature had a greater effect on the %IE than inhibitor concentration, which was consistent with Taguchi's findings. In ANN analyses, five networks were suggested: linear, a generalized regression neural network (GRNN), radial basis functions (RBF), and two multi-layer perceptron (MLP) networks. The highest correlation coefficient (0.996) and lower absolute error (0.126) were achieved by MLP 2:2-9-4-1:1.

선삭 가공 공정에서 절삭력에 미치는 영향에 대한 실험계획법을 이용한 가공성 평가

The exorbitant costs in turning manufacturing can be reduced by moderating the costs added to manpower and processes. There has been an increasing trend of relying on numerous machining tests, based on the field experience of the operator, to obtain optimal cutting conditions. As the automobile-parts sector advances, flexible changes in the cutting conditions are required in industrial settings. This study presents an effective method for obtaining the optimal cutting conditions using the Taguchi method, which is the most commonly used experimental design method. The optimal cutting conditions were obtained by formulating a cutting plan based on a minimal experimental design. Furthermore, the average value of the S/N ratio in the Taguchi method was calculated to derive the predicted values of the cutting force and surface roughness for the turning process conditions.

Enhancing Drilling Performance in Natural Fiber-Reinforced Biocomposites Using Taguchi Method for Sustainable Manufacturing

The current research work focuses on optimizing drilling parameters for Sesbania rostrata fiber-reinforced polycaprolactone (PCL) biocomposites using the Taguchi method and ANOVA to improve hole quality, particularly to minimize delamination. The Taguchi L9 orthogonal array was employed with three factors: spindle speed (300, 750, and 1800 rpm), feed rate (0.05, 0.12, and 0.25 mm/rev), and drill size (4, 8, and 10 mm). The experimental results showed that drill size had the most significant effect on thrust force, with a contribution rate of 99.29%, whereas spindle speed primarily influenced delamination, contributing 67.65%. Optimal parameters were determined to be a spindle speed of 300 rpm, a feed rate of 0.25 mm/rev, and a drill size of 10 mm. These findings are significant for industries using biocomposites, offering sustainable solutions with enhanced machining performance.

Pot Skirt Configuration on the UB-03 Biomass Stove: Taguchi Approach Optimization

A biomass stove is a technology that can utilize biomass fuel as an alternative energy source. This stove is considered effective for saving fossil energy because it uses fuels such as wood, waste, and plants so that it can reduce the effects of global warming because it can minimize the emissions it produces. In its technological development, UB-03 is a biomass stove product with compact construction and affordable prices for rural communities. However, there needs to be an increase to produce more efficient performance. In this case, additional configurations in the form of a pot skirt can be used to increase the efficiency of the biomass stove. The pot skirt is a device that focuses the fire’s direction on the load to minimize wasted heat and increase the efficiency of the biomass stove. This study used the Water Boiling Test (WBT) method for experimental testing. In addition, the Taguchi method was used to analyze the data obtained. This study aims to determine the optimum conditions of the biomass stove with the addition of a pot skirt using the Taguchi method with orthogonal array L9 (33) with three factors, namely angle (64°, 65°, 66°), number of holes (9,10,11) and hole diameter (0.8 cm, 1 cm, 1.2 cm). The results of this study indicate that the optimal configuration obtained is by adding a pot skirt at an angle of 65° with 9 holes and a hole diameter of 1 cm, where the highest efficiency value is obtained, namely 21.19%.

Influence of WEDM input variables on the machinability of Ni–Cu superalloy

ABSTRACT The study investigates the influence of Wire-cut Electrical Discharge Machining (WEDM) input variables on the Ni–Cu superalloy, crucial in marine environments. Input variables include Input current (Ic), Pulse on Time (TON), Pulse off Time (TOFF), Servo Voltage (SV), and Wire Feed (WF) rate, while output variables are Machine Speed (Mc), Kerf Width (K), and Material Removal Rate (MRR). Utilizing an L16 orthogonal matrix, experiments were conducted. The Taguchi method examines single output variables, while the Grey Relational Grade Algorithm (GRA) assesses multi-objective outputs. GRA identifies optimal input combinations, crucial for maximizing the machining performance. ANOVA of GRA results highlights Pulse on Time (TON), Input current (Ic), and Servo Voltage (SV) as significant factors affecting Mc, K, and MRR. This analysis underscores their importance in optimizing the WEDM process for Ni–Cu (MONEL K-500 superalloy).

Enhancing precursor stability with suitable additives to enable blade-coating of organic-inorganic hybrid perovskites at room temperature for efficient perovskite solar modules

In this study, room temperature blade coating organic-inorganic hybrid perovskite (OIHP) films with the precursors made of adding additives such as dimethyl sulfoxide (DMSO), N,N-dimethylformamide (DMF), and N-methyl-2-pyrrolidone (NMP) to the volatile solvent of 2-methoxylethanol (2-ME) were explored. Unlike NMP, DMSO and DMF interact with the perovskites to form Lewis adducts, suggesting important factors beyond the Gutmann donor number and dielectric constant, such as molecular structure, influence adduct formation. The OIHP solar cells made of the precursors with optimized amount of DMSO, DMF and NMP showed the efficiency of 16.5 %, 16.1 % and 8.3 %, respectively. After optimizing the blade-coating process for OIHP film formation by using the Taguchi's method, the optimized OIHP solar modules (active area = 25.2 cm2) achieve PCEs of 14.6 % and 14.1 % with the precursor added 20 mol% DMSO and 30 mol% DMF, respectively. Moreover, the precursor added with DMF demonstrates better storage stability than that of DMSO, achieving the best module PCE of 13.4 % fabricated from the 3-day stored DMF-added precursors, while the module fabricated from the DMSO-added precursor shows a PCE of 9.1 %.

Enhancing bending strength in continuous drive friction welding of PEEK polymer cylinders through the innovative progressively increased welding area method

The continuous drive friction welding (CDFW) stands out for its low energy consumption within the welding realm. Polyetheretherketone (PEEK) represents a high-performance engineering thermoplastic, falling under the polyaryletherketone family. Renowned for its outstanding mechanical, thermal, and chemical attributes, PEEK finds utility across a diverse array of industries. However, the discovery of numerous voids at the weld interface has revealed limitations in the mechanical properties of PEEK welded samples. This study introduces an innovative approach named progressively increased welding area (PIWA) method, to mitigate voids within the weld interface. In general, the Taguchi method was used to optimize the process parameters of CDFW of dissimilar PEEK round rods to reduce random efforts by the trial-and-error method. It was found that the proposed PIWA method can definitely enhance the bending strength of rotational friction welded samples due to reduction of voids inside the weld interface. The optimal process parameters for the CDFW with the PIWA method involve a rotational speed of 2500 rpm, a cone angle of 120°, a cone top width of 8 mm, and a feed rate of 0.1 mm/s. The most influential factor affecting the bending strength of the PEEK welded samples is the feed rate, followed by cone angle, rotational speed, and cone top width. Specifically, the contribution ratios for feed rate, cone angle, rotational speed, and cone top width are about 71 %, 20 %, 7 %, and 2 %, respectively. The confirmation tests showed that the bending strength of the PEEK welded samples using optimal process parameters can be increased by approximately 68 % compared with the maximum bending strength of 180 MPa using the conventional method with a cone angle of 180° The proposed PIWA method has industrial applicability and practical value because this technique can enhance the mechanical properties of PEEK welded samples under low environmental pollution and energy consumption.

Optoelectronic effect of Al-based buffer layers on Al-doped ZnO thin transparent conductive films on flexible substrates

AZO (Al-doped ZnO) film is a transparent conductive film that offers a simple preparation process, low cost, non-toxicity, and excellent stability. It serves as a high-quality material extensively used in liquid crystal displays, solar cells, and other fields. In this study, AZO thin films were prepared on a PET substrate with an Al2O3 buffer layer using the magnetron sputtering method. The deposition parameters were optimized through the Taguchi method and Grey Correlation Analysis. The results demonstrate that the optimal deposition parameters for achieving superior photoelectric properties during the fabrication of AZO films are 100 W (radio frequency power), 1.0 Pa (sputtering pressure), 20 min (coating time), and 20 °C (substrate temperature). Furthermore, the incorporation of an Al2O3 buffer layer enhances the quality of AZO film on PET substrate. This investigation successfully deposited uniform and highly efficient AZO thin films onto flexible PET substrates at low temperatures, thereby expanding their potential applications in flexible electronics.

Identification and isolation of efficient phenol-degrading and heavy metal-resistant bacteria from seasonal catchments of the Lut Desert

ABSTRACT The present study was conducted to isolate and identify a phenol-degrading bacterial strain resistant to cadmium obtained from seasonal catchments of the Lut Desert, Iran. Additionally, optimal conditions affecting biological phenol degradation, including pH, temperature, salinity, and carbon-to-nitrogen ratio, were determined using the Taguchi method, and the ability of the purified strain to degrade phenol in different concentrations was investigated. Isolated bacterium strain Bacillus cereus LD-1, capable of phenol degradation and cadmium tolerance, could tolerate and degrade phenol up to a concentration of 1,500 mg/L. All optimized factors except carbon-to-nitrogen ratio had a significant effect on the rate of phenol biodegradation. Among the selected factors, based on the effect size, pH had the highest impact (10.02), followed by salinity (6.16), temperature (5.61), and C:N ratio (2.55) on phenol biodegradation. The optimal conditions for phenol biodegradation were determined as pH of 8, temperature of 30 °C, salinity of 0 g/L, and C:N ratio of 100:30. Under optimal conditions, 80.57% of phenol was decomposed by the LD-1 strain. Considering the high ability of the isolated strain for phenol degradation in the presence of 100 mg/L cadmium, LD-1 can be applied in the biological treatment of phenolic effluents contaminated with heavy metals.

Taguchi's RT method with sparse principal component analysis

Taguchi's RT method with sparse principal component analysis