Taguchi Method Research Articles

High-quality utilization of raw coke oven gas for hydrogen production based on CO2 adsorption-enhanced reforming

To realize the high-quality utilization of raw coke oven gas (RCOG), the adsorption-enhanced steam reforming process was purposed for hydrogen production, coupled with the sensible heat recovery and the conversion of the high-energy components (such as tar). For this process, the hydrogen production performance and energy utilization efficiency were focused via reforming experiment and process simulation. Using the prepared bifunctional catalyst (Ni/Ce–CaO–Ca12Al14O33), the enhanced reforming experiment was conducted based on orthogonal design and Taguchi method. Compared to S/C ratio (the mole ratio of steam to carbon in the simulated RCOG) and WHSV (weight hourly space velocity), reforming temperature shows a higher sensitivity to hydrogen production. At 800 °C, the produced H2 amount can achieve 3.86 times of that in the initial RCOG and the H2 concentration in the produced gas can reach 88.38 %, when the S/C ratio was 15 and the WHSV was 0.0847 h−1. Based on the established process model, the energy consumption of RCOG enhanced reforming system was discussed. Compared to traditional hydrogen production technologies, this novel process exhibits a lower energy consumption, just about 62.5 MJ/kg H2, and also shows a higher energy conversion efficiency.

Efficiency Improvement for Chipless RFID Tag Design Using Frequency Placement and Taguchi-Based Initialized PSO.

Frequency encoding chipless Radio Frequency Identification (RFID) tags have been frequently using the radar cross section (RCS) parameter to determine the resonant frequencies corresponding to the encoded information. Recent advancements in chipless RFID design have focused on the generation of multiple frequencies without considering the frequency position and signal amplitude. This article proposes a novel method for chipless RFID tag design, in which the RCS response can be located at an exact position, corresponding to the desired encoding signal spectrum. To achieve this, the empirical Taguchi method (TM), in combination with particle swarm optimization (PSO), is used to automatically search for optimal design parameters for chipless RFID tags with a fast response time, to comply with the frequency encoding requirements in the presence of the mutual coupling effect. The proposed design method is validated using I-slotted chipless tag structures that are fabricated and measured with different sets of resonant frequencies.

Investigation of aerodynamic effects and dominant design variables of cavity squealer-tip in three-dimensional performance of a centrifugal compressor

Enhancing the performance of turbomachines has been a longstanding area of interest, with numerous geometry modification methods proposed in the literature. One such method, historically prevalent in turbines, is the cavity squealer tip. However, its application in compressors, particularly of the centrifugal type, remains relatively underdeveloped. This study employs the Taguchi method's L-9 orthogonal array as a sensitivity analysis (utilizing Design of Experiments) to investigate the impact of cavity squealer design variables on the performance of the NASA-CC3 compressor at three key operational points: choke, design, and near stall regions. Computational fluid dynamics is utilized to derive performance parameters, and various sets of design variables result in improvements across pressure ratio, isentropic efficiency, mass flow rate, and surge margin. Notably, a significant 20 percent enhancement in surge margin is achieved in one instance. The performance at the remaining operating points varies among the nine cases, with improvements observed in some areas and declines in others. Processing the data yields three optimal geometries, with the best configuration enhancing all performance parameters (0.59% for design mass flow rate and 2.20% for efficiency, maintaining a constant pressure ratio compared to the base). As anticipated, the optimal impellers exhibit reduced flow leakage compared to the baseline.

Hardness and microstructure of FDM 3D printed parts using self-made PLA-brass filaments

Technological advancements in the industrial sector have led to rapid developments in 3D printing technology, enabling the creation of three-dimensional prototype models. Various filaments, including polyethylene terephthalate glycol, nylon, and polylactic acid, have been widely adopted in the industry. However, filaments composed of metal mixtures are relatively scarce in Indonesia, primarily available only through select online shops worldwide. The production and sale of such filaments present lucrative opportunities within the manufacturing industry. In this research, an experimental study was conducted to examine the hardness of test specimens fabricated using PLA-brass filament. The objective was to identify the optimal hardness value of the specimens. The study focused on three key parameters: nozzle temperature, layer height, and print speed, each at two different levels. The Taguchi L4(2³) experimental design was employed, along with S/N ratio and ANOVA analysis, to evaluate the results. The findings revealed that specific combinations of parameters yield favorable hardness values, as determined by the Taguchi Method. The optimal set of parameters for achieving good hardness values was determined to be a nozzle temperature of 230°C, a layer height of 0.2 mm, and a print speed of 40 mm/s. These results enhance the understanding of PLA-brass filament properties and facilitate the utilization of 3D printing technology in the manufacturing industry.

Analysis of Product Quality Control Using the Taguchi Method and Principal Component Analysis (PCA) at the Pabrik Tahu Alami

Indonesia's rapid economic growth in the global business sector has intensified competition among entrepreneurs, necessitating stringent control over product quality for companies to sustain their market position. This study utilizes the Taguchi method and Principal Component Analysis (PCA) to enhance quality control processes. The Taguchi method focuses on offline quality control with a single response, while PCA is employed for multiple responses. Experiments were conducted at Pabrik Tahu Alami, examining four factors: soybean rate, soaking time, boiling time, and whey water rate, each at three levels. The optimal combination determined was 3 kg of soybeans (level 1), 4 hours of soaking time (level 1), 20 minutes of boiling time (level 2), and 5 litres of whey water (level 2). These results provide a robust framework for optimizing product quality in similar production settings.

Influence of Drafting System Variables at Speed Frame on Yarn Tenacity and Breaking Elongation Using Taguchi Method

Influence of Drafting System Variables at Speed Frame on Yarn Tenacity and Breaking Elongation Using Taguchi Method

Design optimization and experimental verification of ultrasonic stack for micro hot embossing of polymers

Ultrasonic micro hot embossing (UMHE) is a prominent technique used in numerous sectors to produce micro parts since it is cheaper, faster, and more accurate. Amplitude uniformity is a crucial parameter in UMHE in order to manufacture micro parts with accurate dimensions and high-quality surfaces, even though limited research has been conducted on the uniformity of ultrasonic amplitude at the horn face during the embossing process. This paper presents an experimental and numerical study for designing an ultrasonic transducer and horn tailored to the micro hot embossing of polymer micro parts. A finite element (FE) simulation model combined with the Taguchi method has been developed to optimize the horn geometry and maximum amplitude uniformity. The Taguchi orthogonal array of 25 design runs has been generated and simulated using the developed FE modal analysis model, and then the optimized geometry was used to fabricate the horn. Applied torque and operating time calibrate and evaluate the transducer vibration characteristics. Experimental and simulation results revealed that the fabricated ultrasonic transducer and horn of a straight microfeature has a natural frequency of 28.8 kHz and has an 11 µm average peak-to-peak amplitude with 0.963 amplitude homogeneity along the microfeature face. The achieved frequency separation was greater than 0.85 kHz, whereas the gain ratio was 1.2. The design methodology developed in this paper showed great potential and has been numerically validated for various microfeature shapes across the horn face. Consequently, it can be applied to various ultrasonic applications beyond UMHE.

Effects of process parameters on the surface characteristics of laser powder bed fusion printed parts: machine learning predictions with random forest and support vector regression

Laser powder bed fusion (L-PBF) fuses metallic powder using a high-energy laser beam, forming parts layer by layer. This technique offers flexibility and design freedom in metal additive manufacturing (MAM). However, achieving the desired surface quality remains challenging and impacts functionality and reliability. L-PBF process parameters significantly influence surface roughness. Identifying the most critical factors among numerous parameters is essential for improving quality. This study examines the effects of key process parameters on the surface roughness of AlSi10Mg, a widely used aluminum alloy in high-tech industries, fabricated by L-PBF. Part orientation, laser power, scanning speed, and layer thickness were identified as crucial parameters via cause-and-effect analysis. To systematically examine their effects, the Taguchi method was employed within the framework of the design of experiment (DoE). Experimental results and statistical analysis revealed that laser power, scanning speed, and layer thickness significantly influence surface roughness parameters: arithmetic mean (Ra) and root mean square (Rq). Main effect plots and energy density analyses confirmed their impact on surface quality. Microscopic investigations identified surface flaws such as spattering, balling, and porosity contributing to poor quality. Given the complex interplay between parameters and surface quality, accurately predicting their effects is challenging. To address this, machine learning models, specifically random forest regression (RFR) and support vector regression (SVR), were used to predict the effects on surface roughness. The RFR model’s R2 values for predicting Ra and Rq are 97% and 85%, while the SVR model’s predictions are 85% and 66%, respectively. Evaluation metrics demonstrated that the RFR model outperformed SVR in predicting surface roughness.

Application of the Taguchi method and RSM for process parameter optimization in AWSJ machining of CFRP composite-based orthopedic implants

Abstract Abrasive water suspension jet (AWSJ) machining on carbon fiber-reinforced polymer (CFRP) composite-based orthopedic implants yielded insightful results based on experimental data and subsequent statistical validations. Underwater AWSJ cutting consistently outperformed free air cutting, with numerical findings demonstrating its superiority. For instance, at #100 abrasive size and 5 mm standoff distance (SOD), the material removal rate (MRR) peaked at 2.44 g/min with a kerf width of 0.89 mm and a surface roughness (SR) of 9.25 µm. Notably, the increase in abrasive size correlated with higher MRR values, such as achieving 2.15 g/min at #120 grit and 3 mm SOD. Furthermore, optimization techniques like the Taguchi method and response surface methodology (RSM) were applied to refine machining parameters. These methodologies enhanced MRR, exemplified by achieving 2.10 g/min with #120 abrasive size and 5 mm SOD in underwater cutting conditions. The research explored the impact of key process parameters, namely, the speed, feed, and SOD on the MRR, kerf width, and SR in both free air cutting and underwater cutting conditions, which is one of the novel research endeavors in the domain of abrasive jet machining of composites.

OPTIMIZATION OF MACHINING AA4015/B4C METAL MATRIX COMPOSITES BY TAGUCHI METHOD

This research investigates the impact of dry machining AA4015/B4C MMCs (metal matrix composites) utilizing an uncoated B4C insert on Flank wear (VBc) and surface roughness (Ra). This work attempts to close the knowledge gap on the effects of cutting parameters (feed, depth of cut, and speed) on tool wear and surface quality in machining technology. The primary rationale lies in optimizing machining processes for MMCs, known for their challenging machinability due to their tough metallic matrix and hard ceramic reinforcement. The study’s significance is underscored by the exploration of optimal processing parameters to minimize Flank wear and improve surface roughness, crucial factors influencing component quality and lifespan. Specifically, the research identifies v1-f1-d3 (VBc) and v3-f1-d3 (Ra) as the best process parameter combinations, significantly reducing both VBc and Ra. The obtained mathematical models for VBc and Ra provide statistically significant insights into the relationships between cutting variables and performance characteristics. The employment of Taguchi’s L9 orthogonal array proves invaluable in achieving these optimized process parameters efficiently. The Taguchi method’s advantage lies in its ability to systematically explore numerous variables and their interactions with minimal experiments. By reducing the number of trials required, this methodology streamlines the optimization process, saving time, resources, and costs while delivering enhanced machining performance for MMCs. This research, through its systematic approach and emphasis on optimized parameters, contributes to the advancement of machining techniques for MMCs, holding implications for various industrial applications demanding high-performance materials.

Tribological study of magnesium-based AZ91/TiC/rGO hybrid composite prepared by powder metallurgy route: an experimental and analytical approach

ABSTRACT In this research, hybrid composites of magnesium alloy (AZ91) reinforced with titanium carbide (TiC) and reduced graphene oxide (rGO) were studied. The powder metallurgy method was used to synthesise magnesium alloy-based hybrid composites. The tribological behaviour of fabricated composite samples was examined using a pin-on-disc tribotester per the ASTM G99 standard. Using the Taguchi method, the design of the experiment (DOE) was constructed. The L9 orthogonal array opted for tribo-performance evaluation. Also, an ANOVA and regression analysis were carried out to ascertain the relative impact of the tribological factors on the responses. In the present investigation, three variable factors were considered, i.e. reinforcement percentage of TiC (0–10%) keeping constant 0.5 wt.% rGO, disc sliding velocity (0.5 to 1.5 m/s), and applied load varies between 10 and 30 N. It was found that the load parameter had a considerable impact on both the wear rate (WR) and the coefficient of friction (COF). Sliding velocity, on the other hand, had a minimal effect on WR. The concentration of reinforcement exhibits a moderate effect. Taguchi’s predictive results were also compared with experimental results. The worn surfaces were analysed using scanning electron microscopy (SEM), and surface roughness was used for wear mechanics analysis.

Investigation of Friction Stir Welding of Additively Manufactured Biocompatible Thermoplastics Using Stationary Shoulder and Assisted Heating.

Additive manufacturing (AM), also known as 3D printing, offers many advantages and, particularly in the medical field, it has stood out for its potential for the manufacture of patient-specific implantable devices. Thus, the unique properties of 3D-printed biocompatible polymers such as Polylactic Acid (PLA) and Polyetheretherketone (PEEK) have made these materials the focus of recent research where new post-processing and joining techniques need to be investigated. This study investigates the weldability of PLA and PEEK 3D-printed plates through stationary shoulder friction stir welding (SS-FSW) with assisted heating. An SS-FSW apparatus was developed to address the challenges of rotating shoulder FSW of thermoplastics, with assisted heating either through the shoulder or through the backing plate, thus minimizing material removal defects in the welds. Successful welds revealed that SS-FSW improves surface quality in both PLA and PEEK welds compared to rotating shoulder tools. Process parameters for PLA welds are investigated using the Taguchi method, emphasizing the importance of lower travel speeds to achieve higher joint efficiencies. In PEEK welds, the heated backing plate proved effective in increasing process heat input and reducing cooldown rates which were associated with higher crystallinity PEEK. Despite these findings, further research is needed to improve the weld strength of SS-FSW with these materials considering aspects like tool design, process stability, and 3D printing parameters. This investigation emphasizes the potential of SS-FSW in the assembly of thermoplastic materials, offering insights into the weldability of additively manufactured biocompatible polymers like PLA and PEEK.

Optimization of activated carbon production from cajuput biomass as a desiccant

Abstract Effective food preservation methods encompass a range of approaches, among which drying stands out for its convenience in storage and distribution. The drying process and subsequent storage of food, however, are significantly influenced by environmental conditions. To address this, the utilization of activated carbon derived from renewable biomass sources emerges as a sustainable solution for moisture sorption applications. This research delves into optimizing the production of activated carbon from cajuput biomass, harnessing its exceptional desiccant properties through the Taguchi method. The study rigorously investigates crucial parameters, namely carbonization temperature (400, 600, 800 °C), carbonization time (1, 2, 3 hours), NaOH concentration (1, 2, 3%), and impregnation time (1, 2, 3 hours). Employing a two-step approach involving carbonization followed by chemical activation with NaOH, the impact of these variables on the activated carbon’s moisture adsorption capacity is comprehensively evaluated. Remarkably, the optimized conditions of carbonization temperature at 400 °C, carbonization time of 3 hours, NaOH concentration of 3%, and impregnation time of 3 hours yield a maximum moisture adsorption capacity of 0.4076 g/g. These findings emphasize the transformative potential of cajuput biomass as a valuable feedstock for producing activated carbon, endowed with remarkable moisture sorption attributes. This cajuput-derived activated carbon presents an alternative desiccant for efficient moisture adsorption in the food drying process and optimal moisture control during food product storage.

Numerical and experimental investigation of the effect of heat input on weld bead geometry and stresses in laser welding

Abstract Nowadays, laser welding is a powerful joining method. Thanks to the advantages it has, its usage area is increasing day by day. However, getting the desired result from the laser welding process is possible with the proper welding parameter selections. Otherwise, many problems may be encountered, including significantly incomplete penetration. For this reason, parameter selection has been discussed in many studies in the literature. At this point, validated numerical simulation models are precious. Since these models reduce experiment costs and save time. Especially numerical simulation of the structural steel, which is the one of most used materials, is crucial. In this study, the effects of laser power (LP) and welding speed (WS), which are among the vital parameters of laser welding, on weld width and stress were investigated numerically and statistically. Structural steel was selected as the material, and the Taguchi method was carried out for the simulation case study design. Simufact Welding software was used for simulation studies, and simulations were carried out thermomechanical. Thus, more realistic results were obtained via the thermomechanical method. One of the simulation results was verified through an experimental study. The results were evaluated with signal-to-noise (S/N) ratio and a statistical analysis of variance (ANOVA), and as a result of the study, it was seen that the welding speed was a more effective parameter, the optimal parameter combination was found to be 3500 W for laser power and 40 mm/s for welding speed to get maximum weld width and minimum equivalent stress. In addition, it was observed that correctly created simulation studies may provide very close results to experimental studies.

Treatment of Reactive Orange 16 Dye-Bearing Wastewater by Electro-Fenton Process with Stainless-Steel Electrodes: Statistical Optimization and Operational Analysis

Abstract: In the current work, the Electro-Fenton (EF) based Reactive Orange 16 (RO16) dye treatment was studied and compared with central composite (CC) and Taguchi design (TD) statistical optimization tools. Color removal (RC) and COD decay (RCOD) were chosen responses for the effect of pH (A), electrolysis time (B), initial dye concentration (C), and current density (D). The facecentred CC design and L16 orthogonal array were used in the experimental procedures. At optimal conditions, the coefficient of determination (R2) values of 0.99 for CC and 0.97 for TD suggest statistical significance and good model agreement. The results of the ANOVA and Prob. > F values supported the model’s successful experimental data fitting. Taguchi method was found as an appropriate methodology for parameter percentage contributions with fewer experimental runs. Moreover, the S/N ratio charts proved to be a successful CC design replacement. The current density and pH were found to be the most important factors for the EF process. A higher biodegradability (BOD5/COD) and minimum iron concentration (0.45 mg/L) in the effluent sludge demonstrated good environmental disposal suitability. In the last, the effect of various inhibitors/scavengers (SO4 −2, PO4 −3, EDTA, etc.) on the EF process performance was also carried out.

Strength, Microstructure, and Life Cycle Assessment of Silicomanganese Fume, Silica Fume, and Portland Cement Composites Designed Using Taguchi Method

Strength, Microstructure, and Life Cycle Assessment of Silicomanganese Fume, Silica Fume, and Portland Cement Composites Designed Using Taguchi Method

Failure analysis in predictive maintenance: Belt drive diagnostics with expert systems and Taguchi method for unconventional vibration features

Predictive maintenance to avoid fatigue and failure enhances the reliability of mechanics, herewith, this paper explores vibrational time-domain data in advancing fault diagnosis of predictive maintenance. This study leveraged a belt-drive system with the properties: operating rotational speeds of 500–2000 RPM, belt pretensions at 70 and 150 N, and three operational cases of healthy, faulty and unbalanced, which leads to 12 studied cases. In this analysis, two one-axis piezoelectric accelerometers were utilized to capture vibration signals near the driver and pulley. Five advanced statistics were calculated during signal processing, namely Variance, Mean Absolute Deviation (MAD), Zero Crossing Rate (ZCR), Autocorrelation Coefficient, and the signal's Energy. The Taguchi method was used to test the five selected features on the basis of Signal-to-Noise (S/N) ratio. For classifications, an expert system was used based on artificial intelligence where a Random Forest (RF) model was trained on untraditional parameters for optimizing the accuracy. The resulted 0.990 and 0.999, accuracy and AUC, demonstrate the RF model's high dependability. Evidently, the methodology highlights the features potential when progressed into expert systems, which advances predictive maintenance strategies for belt-drive systems.

Multi-response optimization in laser processing technologies by applying desirability function approach and response surface methodology based on grey relation analysis

Laser processing technologies are among the leading industry technologies for efficient and economical processing of a wide spectrum of engineering materials. The determination of optimal parameter settings with respect to multiple and opposite process performances is of great practical importance in laser processing technologies. This paper discusses, analyzes, and compares two main approaches for multi-response optimization (MRO) in engineering, that is, desirability function approach (DFA) and grey relation analysis (GRA), while solving five case studies, covering different laser processing technologies, such as cutting, drilling, welding, micro-channeling, and cladding. In each case study the MRO solutions obtained with two competitive approaches were assessed using the relative target deviation (RTD) criterion. Analysis of the obtained MRO solutions and comparative analysis with results from previous studies indicate that the integrated RSM-GRA provide similar and comparable solutions with the hybrid Taguchi method and GRA, while DFA proved to be a better and more promising approach for solving MRO in laser processing technologies. Some specific features, limitations, and possibilities of MRO approaches were also discussed.

Numerical simulation of JAG-type corrugated plate structure optimization and enhanced heat transfer by pulsating flow

The paper presents a numerical investigation of the structural optimization of a JAG-type corrugated plate and enhanced heat transfer under pulsating flow based on the research results that have been achieved. Firstly, the corrugation pitch, corrugation depth, and corrugation inclination of the corrugated plate were optimized using Taguchi method to obtain the best heat transfer performance. Secondly, a detailed study is carried out on the flow and heat transfer characteristics under different pulsation velocities (0.01 m/s∼0.1 m/s), frequencies (0.4Hz–3.2Hz), and amplitudes (0.1–0.9). Additionally, the relationship between the flow variation at the contact tail of the corrugated channel and enhanced heat transfer is elucidated in combination with the field synergy theory. The results demonstrate that the application of pulsation characteristics to fluid flow enhances heat transfer efficiency under different working conditions, with significantly superior heat transfer performance observed at low flow rates compared to high flow rates. Moreover, the modification of amplitude has a greater impact on heat transfer performance compared to changes in frequency and speed conditions. Changing the amplitude can produce a better synergistic effect. The research results can provide important reference for the engineering application of enhanced heat transfer by pulsating flow.

Experimental Investigation on Chemical Mechanical Polishing of ZA27 Alloy Considering Galvanic Corrosion at Zn/Al Interface

To improve the surface integrity of ZA27 alloy, a method of chemical mechanical polishing (CMP) considering the galvanic corrosion at the Zn/Al interface is proposed to treat the surface of ZA27 alloy. Firstly, the electrochemical experiment is carried out to study the influence of the pH, H2O2 concentration, and glycine concentration on corrosion potential between zinc and aluminum. Then the Taguchi method integrated with grey relation analysis and fuzzy inference are used to optimize the CMP parameters of ZA27 alloy. Finally, the prediction model of the MRR and surface roughness Ra is established using the mathematical regression analysis method. The experimental results showed that the minimum zinc-aluminum corrosion potential difference is 14 mV when the pH is 10, H2O2 concentration is 1 wt%, and glycine concentration is 0.4 wt%. The optimum CMP parameter is the polishing pressure of 34 kPa, the polishing plate’s rotational speed of 70 rpm, and the abrasive particle concentration of 15 wt%. After polishing with the optimum CMP parameter, the MRR is 242 nm min−1, and the surface roughness Ra is 13.91 nm. This study demonstrates that the CMP considering the galvanic corrosion at the Zn/Al interface is an effective method for treating ZA27 alloy surface.