Taguchi Orthogonal Array Research Articles

Cysteine-coated Magnetite Nanoparticles for the Removal of Carmoisine Edible Dye from Aqueous Medium.

In this study, cysteine-coated magnetite nanoparticles (Fe3O4@Cys MNPs) were synthesized by chemical method and applied as a recoverable and efficient adsorbent for the removal of carmoisine dye from aqueous solutions. The synthesized MNPs were characterized by FT-IR, XRD, SEM, and TEM studies. The effect of various experimental parameters on the dye removal efficiency was studied using Taguchi orthogonal array design (L16 array). Under the optimum conditions (pH = 2, stirring time = 30 min, adsorbent amount = 0.1 g and without salt addition), more than 92% of carmoisine was removed from the aqueous solutions. The kinetic studies showed rapid adsorption dynamics by a pseudo-second-order kinetic model, confirming that diffusion controls the adsorption process. Dye adsorption equilibrium data were fitted well to the Freundlich isotherm, and the synthesized adsorbent showed high removal efficiency. The obtained results showed that the synthesized MNPs act as a reusable adsorbent for carmoisine removal with an easy procedure.

Green RP-HPLC method for simultaneous quantification of epigallocatechin-3-gallate and rosmarinic acid in lipid-based nanocarriers and biological fluids: Quality by Design-driven optimization and lean six sigma approach

This study presents the development and validation of a reverse-phase high-performance liquid chromatography (RP-HPLC) method for concurrent quantification of EGCG and RA in prepared lipid-based nanocarriers and biological fluids using a QbD approach, greenness assessment, and Six-Sigma methodology. Initially, variations in critical analytical attributes were identified using the Ishikawa fishbone diagram and Risk Priority Number scores. A Taguchi Orthogonal Array design was employed to screen the critical method parameters influencing method development. Systematic optimization of the RP-HPLC method was subsequently achieved using a Box-Behnken design, with the % organic phase, flow rate, and column temperature as the variables. The responses were retention time, tailing factor, and theoretical plates for both EGCG and RA. Chromatographic separation was accomplished with a methanol and 0.1% formic acid (60:40) isocratic flow system on a Phenomenex Luna C18 column (4.6 × 250 mm, 5 μm) at a 1 mL/min flow rate. The method was rigorously validated according to ICH guidelines. Linearity was observed over a concentration range of 2 to 10 µg/mL for both EGCG and RA, yielding correlation coefficients of 0.998 and 0.999, respectively. The LOD and LOQ were determined to be 0.51 µg/mL and 1.54 µg/mL for EGCG, and 0.35 µg/mL and 1.07 µg/mL for RA. Moreover, the %RSD for all validation parameters were consistently below 2%. Forced degradation studies were conducted under acidic, basic, oxidative, and photolytic conditions to elucidate potential degradation pathways and identify degradation products. The developed method was applied to estimate EGCG and RA in prepared lipid-based nanocarriers and biological fluids like blood plasma and urine. Recovery assays in lipid-based nanocarriers, plasma, and urine samples demonstrated excellent recoveries (96.2–102.1%). The method's greenness was assessed using various tools, and its accuracy was evaluated using Six Sigma methodology. Overall, the developed HPLC method offers a rapid, sensitive, and reliable approach for quantifying EGCG and RA, laying the groundwork for their further investigation as anticancer agents, alone and in combination therapies.

Weight loss and electrochemical measurements of aluminum corrosion in diesel fuel and biodiesel prepared via transesterification of waste cooking oil

Recent studies have found potentials in the utilization of biodiesel from renewable energy sources to tackle environmental pollution associated with the release of exhausts from fossil diesel fuel engines. However, it's imperative to investigate the corrosion rate and nature of the engine components fuelled with the biodiesel. This study examines the corrosion rate and nature of aluminum coupon (AC) in fossil diesel fuel (DF) and biodiesel produced from waste cooking oil via transesterification reaction (WCOB) using weight loss and electrochemical measurements. Taguchi Orthogonal Array was used to study the influence of temperature, immersion time, agitation and WCOD/DF volume. Weight loss method revealed highest corrosion rates to be 0.0052 mm y−1 and 0.0381 mm y−1 for AC in DF and WCOB respectively. Corrosion rate increased with increase in immersion time and temperature. A shift in the corrosion potential from -0.192 V to -0.574 V; and -0.178 V to -0.516 V was revealed by potentiodynamic polarization curve for AC in WCOB and DF respectively. Nyquist plots exhibited relatively perfect semicircles of different diameters and similar shape. The developed mathematical models were effective for corrosion rate prediction. Minimum corrosion rates of 1.222 × 10−3 mm y−1 and 1.822 × 10−3 mm y−1 for AC in DF and WCOB are respectively feasible at optimum point. Presence of carbon and oxygen on AC surface; pits formation; and loss of Al ion into WCOB and DF after corrosion were noticed. In conclusion, the corrosion rate of AC in WCOB was higher than the DF counterpart.

Chemoresistive H2S sensor based on PANI/TiO2/CuCl2 nanocomposite impregnated conductive fabric using TOPSIS and Taguchi method

Abstract Conductive polymer/metal oxide nanocomposites have been widely used for chmoresistive gas sensors. PANI/TiO2/CuCl2 nanocomposite(PTCN) impregnated conductive fabric was prepared by in-situ synthesis method. To improve the performance of PTCN impregnated fabric for detecting H2S gas, Taguchi orthogonal array(TOA) is used to experimental design, and best values of factors affecting to the sensing performance are determined using Technique for order preference by similarity to ideal solution (TOPSIS) and Taguchi optimization method. PTCNs were charactierized by SEM, XRD, FTIR. The sensing performances of the proposed sensor such as linear detection range, sensitivity, repeatability and effect of humidity for hydrogen sulfide gas were evaluated.

Design of a novel ternary blended Self-Compacting Ultra-high-performance Geopolymer Concrete

In this research study, the Taguchi orthogonal array (TOA) optimisation method was used to design the optimum mixture proportions of ternary blended Self-Compacting Ultra-High-Performance Geopolymer Concrete (SCUHPGC). The SCUHPGC mixtures, cured at ambient conditions, included Ground Granulated Blast Furnace Slag (GGBFS), Fly Ash (FA), and Silica Fume (SF) as aluminosilicate sources and sodium hydroxide solution and sodium silicate solution as alkaline activators. The effects of six factors at three levels on the compressive strength of SCUHPGC were investigated. The considered factors were the binder content, the ratio of fly ash to ground granulated blast furnace slag (FA/GGBFS), the ratio of silica fume to binder content (SF/Binder content), the ratio of alkaline activator to binder content (AAL/Binder content), the ratio of sodium silicate to sodium hydroxide (SS/SH), and the concentration of sodium hydroxide solution. Twenty-seven SCUHPGC mixtures were evaluated. The slump flow diameter of the optimum SCHUPGC was 740 mm, which satisfies the requirements of self-compacting concrete. The maximum 28-day compressive strength of 132.7 MPa was achieved by the optimum SCUHPGC mixture, which contained a binder content of 1050 kg/m3, a FA/GGBFS ratio of 0.3, an SF/Binder content ratio of 0.05, an AAL/Binder content ratio of 0.4, a SS/SH ratio of 4.0, and an SH concentration of 12 M. The 28-day flexural strength and tensile strength of the optimum SCUHPGC mixture were 9.6 MPa and 4.9 MPa, respectively.

Combinatorial Method for Quality Improvement of the Thrust Plate – A Case Study

Aim: This research aims to mitigate defects in the turning operation of thrust plates used in fighter jet fuel tank assemblies, thereby reducing the rejection rate and improving overall quality. This aligns with the aerospace industry's reliability goals. Background: The thrust plate is a critical component in fighter jet fuel tank assembly, transmitting engine thrust to the airframe. Quality compromises in this component can impair jet performance. It was observed that the thrust plate had a rejection rate of about 2.9% due to various defects. This real- world scenario underscores the importance of our study on the thrust plate and its potential impact on the aerospace industry. The rejection rate underscores its significance and potential for patent by quality improvement in turning of the thrust plate. Objective: The objective is to mitigate turning operation defects on the thrust plate to reduce rejection rates, aligning with aerospace industry reliability goals. Methods: Experimentation encompassed four pivotal factors: turning speed, feed rate, cutting depth, and tool inserts, implemented through Taguchi's Orthogonal Array technique. Grey Relational Analysis was utilized to optimize parameters in thrust plate turning. Specifically, this paper targeted the enhancement of its diameter, surface roughness, and tool life. Results: A single coefficient for the multiple responses, i.e., grey relational grade, has been determined, and optimum levels for the parameters have been identified. Confirmation experiments with the optimal factor level combination were carried out on a sample of thrust plates, and no rejections were observed. Conclusion: An experimental design based on Taguchi’s orthogonal array approach was used to conduct the experiments. The Grey Relational Analysis has been applied to analyze the experimental results and optimize the turning operation process parameters for the responses thrust plate diameter, tool life, and surface roughness. With this, the rejection of the thrust plate has been considerably reduced.

Coupling Taguchi experimental designs with deep adaptive learning enhanced AI process models for experimental cost savings in manufacturing process development

The Aluminum alloy AA7075 workpiece material is observed under dry finishing turning operation. This work is an investigation reporting promising potential of deep adaptive learning enhanced artificial intelligence process models for L18 (6133) Taguchi orthogonal array experiments and major cost saving potential in machining process optimization. Six different tool inserts are used as categorical parameter along with three continuous operational parameters i.e., depth of cut, feed rate and cutting speed to study the effect of these parameters on workpiece surface roughness and tool life. The data obtained from special L18 (6133) orthogonal array experimental design in dry finishing turning process is used to train AI models. Multi-layer perceptron based artificial neural networks (MLP-ANNs), support vector machines (SVMs) and decision trees are compared for better understanding ability of low resolution experimental design. The AI models can be used with low resolution experimental design to obtain causal relationships between input and output variables. The best performing operational input ranges are identified for output parameters. AI-response surfaces indicate different tool life behavior for alloy based coated tool inserts and non-alloy based coated tool inserts. The AI-Taguchi hybrid modelling and optimization technique helped in achieving 26% of experimental savings (obtaining causal relation with 26% less number of experiments) compared to conventional Taguchi design combined with two screened factors three levels full factorial experimentation.

The Versatility of the Taguchi Method: Optimizing Experiments Across Diverse Disciplines

AbstractThe Taguchi method, a robust experimental design technique, establishes a strong connection between input and output variables. Known for its capacity to yield precise results with fewer trials and minimized errors, this method has gained widespread application in various fields such as engineering, physics, chemistry, economics, finance, and more. In this paper, the authors examine the importance of the Taguchi orthogonal array method, its step-by-step optimization procedure, and its potential for future applications. Through a thorough literature review, the authors investigate how the Taguchi method has been effectively employed to identify key factors influencing response variables. The versatility of the Taguchi method becomes apparent when considering its applications across diverse disciplines. Researchers in engineering have successfully utilized this technique to optimize processes and enhance product quality. Furthermore, in scientific fields like physics and chemistry, the Taguchi method has proven invaluable for conducting experiments efficiently, resulting in more accurate and reproducible outcomes. Researchers gain critical insights into the effects of factors on the response variable by employing statistical tools such as mean analysis, variance analysis, and signal-to-noise ratio. The Taguchi method remains a valuable and broadly applicable tool for optimizing experiments and identifying influential factors across multiple disciplines. This paper’s extensive literature review emphasizes its significance in various fields and outlines the step-by-step procedure to leverage its potential for optimization.

Reliability analysis of cutting tools using transformed inverse Gaussian process-based wear modelling considering parameter dependence

Reliability analysis is crucial for ensuring the performability of the desired function. The cutting tool performs the machining operation at varied conditions to manufacture diverse products. During operation, the tool degrades stochastically in the form of wear. To avoid the unfavourable consequences occurring from severe tool wear, appropriate formulation of the tool reliability, considering threshold degradation level as the failure criterion, is crucial. However, the degradation of the tool during machining is impacted by the current state of the tool wear and operating conditions. Considering these, the present study proposes a state-dependent transformed inverse Gaussian (TIG) process incorporating the effects of operating conditions to develop the tool wear model. In order to evaluate the proposed method, tool wear experiments are conducted at different operating conditions following the Taguchi orthogonal array experimental design. The experimental data are utilised to estimate the parameters of the developed model using the Bayesian approach. Following the parameter estimation, tool reliability is evaluated under varying operating conditions. The comparison of the estimated median time to failure of the tools with the failure time observed in the validation experiments ensures the effectiveness of the proposed model. The proposed approach has the potential to estimate the reliability of the industrial products subjected to state-dependent degradation under varied operating conditions.

Numerical modeling and optimization of fillet height of reinforced SAC305 solder joint in an ultra-fine capacitor assembly

PurposeThis study aims to investigate the design configuration for an optimum solder height of reinforced SAC305 solder joint in an ultra-fine capacitor assembly.Design/methodology/approachA multiphase finite volume model is developed for reflow soldering simulations to determine the fillet height of reinforced SAC305 solder joint in an ultra-fine capacitor assembly. Different solders, namely SAC305-x, SAC305-xNiO and SAC305-xTi, with varying percentage weight compositions of nanoparticles (x = 0 Wt.%, 0.01 Wt.%, 0.05 Wt.%, 0.10 Wt.%, 0.15 Wt.%) are investigated. A reflow soldering experiment is also conducted, and the cross-sections of the reflowed packages are examined using a High-Resolution Transmission Electron Microscope (HRTEM). The optimum design configurations (nanoparticle composition and material) for the solder fillet height are investigated using the Taguchi orthogonal array method.FindingsGood correlations were recorded between the HRTEM micrographs and the numerical predictions of the nanoparticles' distribution in the molten solder. The numerical prediction of the fillet height also agrees with the experiment, with a maximum disparity of 5.43%. It was found that Ti nanoparticles, having the smallest density compared to NiO and, exhibit the highest buoyancy effect in the molten solder. The Taguchi analysis revealed that the nanoparticles' material factor is more significant than the Wt.% factor for an optimum fillet height. An optimum design configuration for fillet height was established as SAC 305–0.15 Wt.% Ti, corresponding to a 41.13% improvement of the plain SAC 305 solder.Practical implicationsThe fillet height of solder joints greatly influences the solder joint reliability of miniaturized electronic packages. Solder joint reliability of ultra-fine capacitors can be improved using this study's findings on the optimum design configuration for the capacitor's solder fillet. The study’s findings can be practically implemented in industries such as electronics manufacturing, where enhanced solder joint reliability is critical.Originality/valueInvestigation of the optimum design configuration for reinforced SAC305 solder fillet is almost nonexistent in the literature. This study explored the optimization of fillet height of reinforced SAC305 solder joints in miniaturized capacitor assembly.

Modulation of chondroprotective hyaluronic acid and poloxamer gel with Ketoprofen loaded transethosomes: Quality by design-based optimization, characterization, and preclinical investigations in osteoarthritis

Osteoarthritis (OA) is a chronic joint disease that results in biomechanical and morphological changes that contribute to cartilage degradation. Ketoprofen (KP), used in the treatment of OA, is a selective inhibitor of cyclooxygenase-2 (COX-2). Topical administration of KP bypasses gastric irritation as well as first-pass metabolism and increases localized delivery. The research intricates fabrication and optimization of KP-loaded transethosomes (KP-TEs) via Taguchi orthogonal array design and Central composite design (CCD). The optimized KP-TEs depicted an average vesicle size of 110.0 ± 1.70 nm, poly dispersibility index (PDI) of 0.103 ± 0.01, zeta potential −6.08 ± 0.27 mV, and conductivity of 0.049 ± 0.0001 mS/cm. The optimized KP-TEs were loaded in composite hyaluronic acid (HA) and poloxamer 407 (Px407) for an improvement of osteotrophic and chondroprotective transethosomal gel. The drug content of KP-TEs-HA/Px407 gel was found to be 90.08 ± 1.25 %. Preclinical research has been carried out by using the monosodium iodoacetate to develop model for osteoarthritis in male wistar rats. The X-ray imaging of KP-TEs-HA/Px407 gel treated group showed intact meniscus, healthy articular joint, and normal synovial lining same as the healthy control group. The IL − 1β IL-6, IL-22, TNF-α, and IL-10, levels, X-ray imaging, and studies on histopathology demonstrated the effectiveness of transethosomal gel in reducing pain and inflammation.

An Approach to Development and In-vivo Evaluation of Beta Sitosterol Phytosomes by Taguchi Orthogonal Array Design.

The research mainly focused on developing and optimizing beta-sitosterol phytosomes through a systematic Taguchi orthogonal array design and assessment of their performance in both beta-sitosterol phytosomes. The fabrication of phytosomes containing β-sitosterol was carried out using the rotary evaporation technique. An orthogonal array design was employed in the study to precisely optimize the phytosomes. In this two responses and three independent variables were analyzed. The data was analyzed by using statistical modeling. Characterization of these phytosomes involves Fourier transform infrared spectroscopy, entrapment efficiency, differential scanning calorimetry compatibility study, zeta potential and particle size. Based on the findings, an optimized phytsome formulation was developed to achieve the best results. The results indicated that beta-sitosterol phytosomes responses are significant. It effectively reduced body weight as well as levels of total cholesterol (126.120 ± 0.98 mg/dl), triglycerides (104.23 ± 2.8 mg/dl), HDL (39.31 ± 0.45 mg/dl), VLDL (21.67 ± 0.34 mg/dl), and LDL (76.43 ± 0.34 mg/dl) in rats compared to the other groups. The orthogonal array design study observed that the anti-hyperlipidemic activity of β-sitosterol was nearly as potent as that achieved with standard drug therapy.

Optimising the quality of several welds in a metal-inert gas arc joining of AA6082 and AA7075 using the grey-based Taguchi technique

In recent times, welding procedures have become increasingly crucial for fabrication and manufacturing businesses. Gas metal arc welding, also known as metal inert gas (MIG) welding, has attracted much attention because of its versatility. Its benefits include low capital needs, high deposition rates, high productivity, and simplicity in adjusting to automation. It has drawn much interest because of its versatility in welding metallic materials and ease of automation. This work's objective is to maximise the multi-performance properties of the aluminium alloys AA6082 and AA7075's MIG-welded butt junction by using a hybrid grey-based Taguchi technique. During MIG welding, With the L9 Taguchi orthogonal array, the welding speed, gas flow rate, and current were optimised. Weld joint integrity has been evaluated using the fusion zone's Vickers microhardness, per cent elongation, tensile strength, and yield strength. The ideal welding current for the MIG process is 140 A, the perfect welding speed is 10 mm/min, and the excellent gas flow rate is 18 lit/min. The material showed 159.68 MPa of tensile strength, 112.79 MPa of yield strength, 16.79% of percentage elongation, and 70.95 HV of hardness under optimal conditions. With a 63.99% contribution to the process, welding speed greatly affected the weldments' overall performance. The confirmatory test confirmed the optimisation procedure also demonstrated that optimising numerous welded joint performance factors may be achieved effectively with the grey-based Taguchi approach.

An artificial bee colony optimization algorithms for solving fuzzy capacitated logistic distribution center problem

This paper presents a methodological approach to solving the fuzzy capacitated logistic distribution center problem, with a focus on the optimal selection of distribution centers to meet the demands of multiple plants. The distribution centers are characterized by fixed costs and capacities, while plant demands are modeled using fuzzy triangular membership functions. The problem is mathematically formulated by converting fuzzy demands into crisp values, providing a structured framework for addressing uncertainty in logistic planning. To support future research and facilitate comparative analysis, 20 benchmark problems were generated, filling a gap in the existing literature. Three distinct artificial bee colony algorithm variants were hybridized with a heuristic: one using the best solution per iteration, another incorporating chaotic mapping and adaptive procedures, and the third employing convergence and diversity archives. An experimental design based on Taguchi's orthogonal arrays was employed for optimizing the algorithm parameters, ensuring systematic exploration of the solution space. The developed methods offer a comprehensive toolkit for addressing complex, uncertain demands in logistic distribution, with code provided for reproducibility.Key contributions include:•Development of a fuzzy model for the selection of distribution centers with fixed costs and capacities under uncertain plant demands.•Generation of 20 benchmark problems to advance research in the fuzzy capacitated logistic distribution center problem domain.•Integration of a heuristic approach with three distinct ABC algorithm variants, each contributing unique methodological insights.

Emerging eco-friendly fiber-reinforced concrete with shaped synthetic aggregates using Taguchi grey relational analysis and utility concept

The present study assessed the applicability of employing Taguchi-based Grey relational analysis (T-GRA) and the Taguchi approach combined with the utility concept (T-UC) for enhancing the mix design parameters of fiber-reinforced synthetic aggregate concrete (FRSAC). Cement was supplemented with binders such as ground granulated blast furnace slag (GGBFS), metakaolin (MK), and lime powder (LP). The optimized mix proportion of FRSAC was determined to enhance the fresh and mechanical performance. Furthermore, this investigation used two weighting approaches: equally weighted and maximum deviation methods. An established L16 (45) Taguchi orthogonal array was used with five different factors, namely, cement replacement (40 %, 50 %, 60 % and 70 %), binder content (B1, B2, B3, B4), water-to-cement ratio (0.31, 0.32, 0.33, 0.34), fiber dosage (0.1 %, 0.2 %, 0.3 % and 0.4 %), and synthetic aggregate replacement (25 %, 50 %, 75 %, and 100 %) were employed to design the experiments. Then, T-GRA and T-UC were used to determine the optimum mix proportions for five response parameters: workability, compressive strength, split tensile strength, elastic modulus, and impact ductility index. Results indicated that the two methods, GRA and UC, can be successfully integrated with the Taguchi method to derive the optimized FRSAC mixture. Confirmation experiments were performed after determining the optimum mix design parameters, including cement replacement of 60 %, binder content of B4, the water-to-cement ratio of 0.34, fiber dosage of 0.1 %, and synthetic aggregate replacement of 75 %. The optimum FRSAC mix was examined for its fresh (workability) and hardened (compressive strength, split tensile strength, elastic modulus, impact ductility index) properties.

Utilizing Taguchi method and in situ X-ray powder diffraction monitoring to determine the influence of mechanical activation conditions on the physico-chemical properties and Al leachability of K-feldspar

K-feldspar represents an important natural resource of potassium and aluminum. Within the framework of this study, the K-feldspar was mechanically activated in a planetary ball mill under different conditions planned according to 43 Taguchi orthogonal array experimental design. As outputs, specific surface area (SBET), median particle size (d50), amorphization degree of mineral phases , and Al recovery were used. It was found that the initial d50 value of 293 μm could be reduced to 6.7 μm and the SBET value of 4.7 m2/g could be increased up to 32.5 m2/g upon milling. Both microcline KAl3SiO8, and albite NaAl3SiO8 could be almost completely amorphized, whereas quartz SiO2 still maintained some crystallinity even under the most intensive conditions. Increasing SBET and decreasing the d50 values did not lead to a significant improvement in Al leach recovery, whereas a clear relationship between the amorphization of microcline and the recovered aluminum was found. Analysis of Variance (ANOVA) showed that increasing ball-to-powder ratio is the most beneficial for the improvement in Al recovery. In situ powder X-ray diffraction monitoring performed in an oscillation ball mill under synchrotron irradiation has shown very rapid amorphization of microcline phase at the beginning. However, amorphization of microcline was only partial after two hours of the treatment in this mill, apart from almost complete process in the planetary ball mill. In the end, regressions for the calculation of Al recovery by knowing the values of input parameters were calculated. In general, by just using mechanical activation without the subsequent roasting process that is commonly used to boost metal recoveries, it was possible to quantitatively recover aluminum from K-feldspar.

Erosion wear of the multilayered high velocity oxy‐fuel ceramic coatings on aluminum alloy composite substrate

AbstractHigh velocity oxyfuel coatings have been sprayed on aluminium (Al) alloy composites substrate with varying coating thickness and tested for their wear behavior. The density and micro‐ hardness of the coatings found to increase with increase in coating thickness. The air erosion wear test has been conducted using quartz sand of size up to 75 μm as erodent. The steady state experiments indicate that the greatest specific erosion rate is at 60° and minimum at 30°. Due to the presence of interlayer, specific erosion rate decreases with the increase in the thickness of the coatings. Surface topography of the eroded samples indicate a decrease in surface roughness with increase in impact velocity. Thereafter, Taguchi (L16) orthogonal array has been utilized in order to optimize the input parameters. Analysis of variance has been applied to determine the contribution of individual control factors. The results from Taguchi experiments and analysis of variance find the order of dominance of control factors and their individual contribution as: velocity (47.31 %) > coating thickness (29.94 %) > angle (13.26 %) > erodent feed rate (7.65 %). Coatings have exhibited a semiductile wear behavior.

Investigation of process parameters for modeling of ceramic composite SiSiC IN dry EDM (DEDM) cutting

The manufacturing industry is currently grappling with issues related to energy dissipation and product quality, both of which significantly impact productivity. In addressing this pertinent concern, this study endeavours to identify the key indicators that contribute a crucial role in machining process. The Dry EDM (DEDM) emerges as a novel technology, wherein environmentally friendly gases serve as an alternative dielectric medium instead of liquid EDM approaches. In conventional EDM process, hydrocarbon oils release toxic emissions while the gases used in Dry EDM process don’t produce harmful emissions and hence make the DEDM process sustainable.An investigation has been carried out to observe the influence of different gases like O2, N2 and Air on Siliconized Silicon-Carbide plate (SiSiC) of ø50mm*2 mm under Dry Electrical Discharge Machining. Effect of different tools is also observed using varying shapes of electrodes like plane Cu electrode of ø6 mm diameter with 60 mm length and tubular shape with outer diameter ø6mm and inner diameter ø5.1 mm with a length of 60 mm. The three gases are one by one supplied through a nozzle in the presence of plane Cu electrode to make the holes in SiSiC plate. The same process is executed with tubular Cu electrode. Modified Taguchi Orthogonal Array is applied to analyze the effect of control factors such as gap voltage, discharge current and pulse on-time through a series of experiments. Effect of different shape of tools and different gases is observed for the material removal rate (MRR) and surface roughness (SR) of specimen.In this paper, a latest DEDM process of swirl assisted flushing is proposed which provides a new technique to solve the problems of low MRR and poor surface integrity. Swirl assisted flushing works on Decay Law and also microscopic investigation justifies its validity. It is concluded by this research that current and Pulse on time are more contributing factors about 53.3 % and 27 % respectively. Furthermore, it is noted that DEDM increases MRR 19.5 % and lowers Ra approximately 2/3 than traditional machining. The MRR of O2 is about 3.1 times more than Air and N2 comes at least position while N2 creates better quality of surface due to formation of an inert nitride layer. Empirical relations are established for SR and MRR using Minitab 18 Software to develop a robust model. Confirmation test is performed to check the validity of developed mathematical model. The Novelty of this research is also extended by introducing a new method SAF. The results are finally evaluated by ANOVA.

Effects of Thermoforming Parameters on Woven Carbon Fiber Thermoplastic Composites.

The quality of woven carbon fiber fabric/polycarbonate thermoplastic composites after thermoforming and demolding was investigated using finite element simulation and the Taguchi orthogonal array. The simulation utilized a discrete approach with a micro-mechanical model to describe the deformation of woven carbon fabric, combined with a resin model. This simulation was validated with bias extension tests at five temperatures. The thermoforming process parameters considered were blank temperature, mold temperature, and blank holding pressure, with three levels for each factor. Optimal values for the fiber-enclosed angle, spring-back angle, mold shape fitness, and the strain of the U-shaped workpiece were desired. The results indicated that the comparison of the stress-displacement curve of bias extension tests verified the application of the discrete finite element method. Results from the Taguchi array indicated that blank holding pressure was the dominant parameter, with the optimal value being 1.18 kPa. Blank temperature was the second most significant factor, effective in the range of 160 °C to 230 °C, while mold temperature had a minor effect. Furthermore, the four quality values are dependent and have a similar trend. The best combination was identified as a blank holding press of 1.18 kPa, a blank temperature of 230 °C, and a mold temperature of 190 °C.

Compressive strength performance of 3D printed PLA/almond shell particles reinforced PLA multi-material composite

The advent of 3D printing has revolutionized the manufacturing landscape, enabling the creation of intricate structures and personalized designs. The use of multi-material polymer composites in additive manufacturing has further expanded possibilities, offering enhanced mechanical properties and advanced functionalities. In the present study, PLA/Almond shell reinforced PLA (PLA/AmdPLA) multi-material composites were developed using Fused Filament Fabrication (FFF) method. The objective of this study is to develop the multi-material and optimize the 3D-Printing Parameters (3D-PP) with respect to Printing Speed (PS), Layer Height (LH), and Printing Temperature (PT), in order to maximize the compressive strength of the composites. The L16 Taguchi orthogonal array was established to systematically study the effects of the 3D-PP on the compressive strength. Through a series of experiments, varying the levels of each 3D-PP, data was collected and analyzed to determine the optimal 3D-PP settings. The results demonstrate that the PLA/AmdPLA multi-material composites achieved its maximum compressive strength when fabricated at a PS of 20 mm/sec, a LH of 0.1 mm, and a PT of 210°C. Furthermore, the findings revealed that the PS and LH significantly influenced the compressive strength, while the PT exhibited moderate effects. The regression analysis results indicate that the compression experiments conducted on the PLA/AmdPLA multi-material composites yielded an error percentage of 4.73%. This suggests a strong agreement between the predicted values obtained from the regression model and the actual experimental results which shows that the model has high accuracy. Therefore, these functional composite materials are recognized for their superior strength, lightweight properties, appealing aesthetics, and sustainable qualities in various consumer applications.