Taguchi Technique Research Articles

The effects of joint process parameters of two-step manufacturing processes on the mechanical performance of biocomposites using Taguchi and multiple regression techniques

This study evaluates the influence of joint parameters of extrusion (extrusion profile temperature) and injection molding (barrel profile temperature and mold temperature) manufacturing processes on the mechanical performance of biocomposite materials via the Taguchi and multiple regression techniques. Statistical analysis of variance (ANOVA) was performed to determine the most influential controllable factors for the individual responses. The results of the study revealed that the mechanical properties of the biocomposites are affected by the joint parameters of the two-step manufacturing techniques. This study will help in the process design of biocomposites with improved mechanical performance.

Exergetic analysis and multiparametric optimization of a novel three‐fluid‐based organic Rankine cycle evaporative system via Taguchi method

AbstractEvaluations were conducted on the thermal performance of an organic Rankine cycle (ORC) system using three fluids as the evaporative system at a low‐grade heat source. The modified ORC evaporators were replaced with a three‐fluid system, which included hot fluids at the top and bottom and an isopentane working fluid in the middle section. Furthermore, the thermal performance assessment with a hot fluid heat transfer ratio in the outer and inner tubes (Q2/Q1) varying from 25:75 to 75:25 has been investigated. The impact of the hot fluid's (Q2/Q1) heat transfer ratios to saturated steam on the modified ORC's thermal performance assessment was examined, with an evaporative temperature range of 45–65°C and a pinch point temperature difference (PPTD) of 3–10°C. The Taguchi technique solves multiparameter optimization using the L9 orthogonal array. The findings showed that in three‐fluid‐based modified ORC systems, the network output, exergetic efficiency, and irreversibility went down with PPTD for all three Q2/Q1 cases. For Q2/Q1 of 75:25, the ORC's energetic efficiency and overall irreversibility reached their optimum, while a PPTD of 3–10°C reduced the exergetic efficiency by 19.71%. Also, Q2/Q1 of 75:25 showed the highest and 200% higher ORC system work done at PPTD of 3°C than Q2/Q1 of 25:75—the lowest. Modified ORC network generation, energy output, and heat transfer rate showed excellent results at an evaporative temperature of 58.33°C. For optimal network productivity, Q2/Q1 of 75:25 was 160% and 40% greater than 50:50 and 25:75 at 58.33°C, respectively. The three‐fluid‐based modified ORC system performs better with a 75:25 Q2/Q1 ratio. According to Taguchi's analysis, evaporation temperature affects the improved ORC system's thermal, exergy, and network generation. Also, heat transfer ratios (F = Q2/Q1) largely affect system irreversibility.

Optimization and Prediction of Wear Characteristics of Khas Khas Grass/Mesquite Bark Powder/Banana Fiber-Reinforced Epoxy Green Hybrid Composites Using Taguchi Technique

Optimization and Prediction of Wear Characteristics of Khas Khas Grass/Mesquite Bark Powder/Banana Fiber-Reinforced Epoxy Green Hybrid Composites Using Taguchi Technique

Multiple solutions of tungsten carbide-cobalt cutting tool turning performance optimization results by Taguchi's combined multiobjective approach analysis an exponentiated exponential Weibull Dagum distribution model

Manufacturers employ various techniques to enhance tool life and influence both production costs and surface finish quality. Recently, cryogenic treatment has gained attention for improving machining performance. In this study, tungsten carbide-cobalt (WC–Co) cutting tools underwent cryogenic treatment at −196 °C for 24 h followed by tempering at 200 °C for 2 h. Machinability characteristics including Tool Wear Rate and Surface Roughness (Ra) were assed for Cryo Treated (CT) cutting tool during spinning operations on Al6063 alloy. This evaluation was compared with an untreated tool. Results demonstrate that the CT tool significantly enhances tool longevity while ensuring a satisfactory surface finish. To optimize the performance of the CT tool in turning processes, multiobjective optimization techniques, namely Taguchi's Grey Relational Analysis and Technique for Order Preference by Similarity to Ideal Solution, were utilized. In this research exponentiated exponential Weibull Dagum (EEWD) model has been utilized with the goal of increasing the tractability of the DGM (Dagum) in modeling the real-world data. The main object of this work, an innovative generalization of the EEWD distribution of Quantile Function (QntFEEWD) has been derived with six parameters. This QntFEEWD is significantly influent in driving measures of position such as the Qutl (quartiles), Octl (octiles), Decl (deciles), Pecl (percentiles), and median of EEWD distribution. The T-R{.} framework has been recently used to generalize different distributions; however, the DGM distribution's viability has not been examined. The T-R{.} combines three distributions, with one acting as a standard distribution. Each distribution's combined potency, which is a weighted hazard function of the baseline distribution, would have more parameters but be able to handle dataset bimodality with great flexibility. In order to generalize the DGM distribution, this paper used the quantile function of the Weibull distribution. The current study presents the EEWD, a novel generalized six parameter (6P) model.

Optimization of Manufacturing Parameters of PLA Components Using Taguchi and Neural Network (NN) Technique

Optimization of Manufacturing Parameters of PLA Components Using Taguchi and Neural Network (NN) Technique

Determining method of optimal process parameters using Taguchi method and technique for order preference by similarity to ideal solution in plastic injection molding

Many plastic injection molding (PIM) process optimization problems are multi-objective optimization problems that optimize multiple mechanical properties. This paper proposed a determining method of optimal process parameters and their effect ranks using Taguchi method and TOPSIS in the PIM. TOPSIS was used to convert multiple mechanical properties into single comprehensive response. It was selected as a reasonable multi-attribute decision-making (MADM) method from among some well-known MADM methods based on mean rank correlation coefficient and mean absolute rank deviation. Taguchi method was used to design experiment and find the optimal process parameters. The proposed method was applied to determine the optimal values of the process parameters: melt temperature (MT), packing pressure (PP), cooling time (CT), and injection pressure (IP) for improving tensile strength, elasticity module, flexural modulus, and impact strength in the PIM with Acrylonitrile-Butadiene-Styrene compound as plastic materials and AISI 1020 as mold materials. The optimal values of the process parameters were MT of 280°C, PP of 28 MPa, CT of 22 s, and IP of 50 MPa, and their effect ranking was IP (51.941%), PP (32.280%), CT (9.045%), and MT (6.734%). The method could be widely applied to not only the PIM process optimization but also various manufacturing process optimization problems.

Enhanced performance of perovskite solar cell by optimization of thin film control parameters using Taguchi method

The objective of the study is to examine the influence of various thin film control parameters on the synthesis of carbon-based passivated perovskite solar cells. Passivation additives, namely MOF UiO-66-NH2 (20 mg/ml) and inorganic additive KPF6 (1 mg/ml), were applied to treat the perovskite solar cells simultaneously. A PSC device of a standard configuration FTO/TiO2/Perovskite layer/Additives/HTL/Carbon electrode is utilized for experimentation. The performance evaluation of the system was carried out using Taguchi method. The critical control parameters considered in the study are: type of perovskite; annealing temperature of perovskite layer; the number of perovskite coating layers; and the type of hole transport layer (HTL). Each parameter is allocated three levels. An orthogonal array was designed using the Taguchi technique to optimize the quality control parameters. The signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were then utilized to determine the ideal combination of parameters. The analysis identified the significant contribution of each parameter to the efficiency of perovskite cells. Among these parameters, the type of perovskite (used in the synthesis process) was found to impact the fabrication and performance of the cells significantly. Furthermore, it was observed that the type of hole transport layer (HTL) employed in the device significantly influences its performance. The best combination for our experiment is found to have FA0.55MA0.25Cs0.20PbI3 as the perovskite-type, an annealing temperature of 120˚C, a double layer of perovskite coating and Spiro-OMeTAD as the HTL. The solar cell is developed for each experiment as well as the validation test.

Evaluation of Material Removal Rate on Various Electrodes for Stainless Steel 316 Material on Die-Sinking EDM by Using Taguchi Technique

Evaluation of Material Removal Rate on Various Electrodes for Stainless Steel 316 Material on Die-Sinking EDM by Using Taguchi Technique

Optimizing Cutting Parameters for Effective Turning of EN-31 Steel by Utilizing Vegetable-Based Cutting Fluids as a Coolant

<div>The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075 mm/rev. A cutting speed of 275 m/min and a feed rate of 1.00 mm/rev led to a lower TWR. The results suggest that the combined use of coconut oil and aloe vera as cutting fluids improves the turning quality of EN-31 steel, particularly when employing a combination of 30% aloe vera and 70% coconut oil. As a possible solution for performance problems in achieving desired results during the turning of EN-31 steels, these recommendations may be used in industries to enhance turning performance.</div>

Optimization of TIG welding process parameters using Taguchi technique for the joining of dissimilar metals of AA5083 and AA7075

This research paper aims to optimize the TIG welding parameters to join dissimilar metals of AA5083 and AA7075 using the Taguchi technique. The TIG welding current and root gap of butt geometry configuration are considered input parameters, and welding characteristics such as tensile strength, 0.2% of yield strength, hardness, and impact energy are output responses. The base metals are joined according to the Taguchi L-09 design of experiments. The welded samples were inspected using the X-ray radiography method for internal defects. Tensile properties, hardness number, and impact energy of different welding coupons were evaluated by conducting the uni-axial testing, a Brinell hardness test, and an Izod impact test, respectively. A better weld strength of 224 MPa was observed at 210 A welding current, and the root gap of 1.5 mm was maintained. Better hardness and impact energy values were observed when the root gap of 1.5 mm and welding current of 220 A were maintained. The root gap is the primary factor influencing tensile strength enhancement, which accounts for 44.78% of the effect, followed by 40.5% welding current. Root gap is the parameter that affects the tensile properties, hardness number, and impact toughness the most. The findings of this paper suggest the optimal parameters for welding AA5083 and AA7075 dissimilar base metals, which are suitable for complex structures requiring both durability and resistance to harsh environments.

Polymethylmethacrylate (PMMA) deposition and removal optimization in CVD-grown graphene transfer: A Taguchi technique study

The conventional method of graphene transfer involving Polymethylmethacrylate (PMMA) often results in residual PMMA, negatively impacting the optical and electrical properties of the transferred graphene layer. This study employs the Taguchi optimization technique to minimize PMMA contamination during the graphene transfer process. The quality of the transferred graphene layer was evaluated utilizing atomic force microscopy (AFM), Raman spectroscopy, and Hall Effect measurement. The optimized conditions identified were a PMMA concentration (P) of 4.5 %, a spin rotation (S) speed of 3000 rpm, an acetone bath temperature (A) at 40 °C, and a dissolution duration (T) of 60 min. These parameters achieved a promising surface coverage of 3.42 %. Interestingly, further characterization highlighted that sample #8, prepared with different parameters (P = 12 %, S = 3000 rpm, A = 24 °C, T = 60 min), exhibited a surface coverage of 5.10 % and superior properties, including high transparency, exceptional film quality, low electrical resistance (8691 Ω), and an ID/IG ratio of 0.13. These findings suggest that the optimized conditions are suitable for applications prioritizing surface coverage, while the parameters for sample #8 are recommended for achieving minimal electrical resistance, high transparency, and superior film quality. This research contributes insights into PMMA-assisted graphene transfer, offering practical guidance for tailored processes.

AISI D2 steel machining and manufacturing process optimization for tooling applications in biomedical industry

Tool steels such as AISI D2 are famous in the manufacturing industry because of their engineering applications. The precise interplay of improved hardness and toughness makes the machining of complex geometries challenging through conventional machining options. Therefore, non-conventional processes such as wire electric discharge machining (WEDM) are preferred because of their simultaneous machining and surface modification actions. To investigate the complex process parameters and their sensitivity, material removal rate (MRR) and cutting surface roughness (SR) are the corresponding performance measure characteristics for WEDM machining on AISI D2 tool steel. The L18 mixed-level Taguchi technique has been used for obtaining combinations of experiments on two levels of thickness and three levels of other remaining factors (21 × 33). Analysis of variance (ANOVA) and signal-to-noise ratio have been applied to measure the magnitude of effects on each control factor, to investigate the optimum levels of input process parameters on machining characteristics, and to identify their significance. ANOVA analysis revealed that, for both responses, all main effect variables are highly significant, with p-values equal to zero. Moreover, the coefficient of determination (R2) value in the ANOVA findings for both responses is above 97%, indicating the high reliability of the model. In addition, the composite desirability (dG) is considered to maximize MRR and minimize the SR during WEDM of D2; the better combination of optimum levels of machining parameters (T = 25.4 mm, Pon = 4 µs, SV = 95 V, and WT = 5 kg-f) has a dG of 0.5614.

Machine Learning and Taguchi Techniques for Predicting Wear Mechanisms of Ni-Cu Alloy Composites

Nickel-Copper alloys hybrid composite was formed in an induction furnace set up on a sand substrate. With different percentages of Al2O3 (3, 6, 9 and 12 wt.%) and TiO2 (constant 9wt.%) reinforcements, the goal is to examine the wear behavior and friction coefficient of Ni-TiO2-Al2O3. The factors considered for the wear analysis were sliding distance (1500, 1000, and 500 m), applied load (25, 50, and 75 N), and sliding velocity (1.46, 2.93, and 4.39 m/sec). The pin-on-disc equipment is utilized to perform different wear tests are carried out using in accordance with the Taguchi L27 orthogonal array. The machine learning used to correlate between actual and anticipated values for both metrics is strong, with a reasonable error margin. The Mean Squared Error (MSE) for the wear rate was 0.1025 (10.25%) in the Linear Regression model and 0.2390 (23.89%) in the Random Forest model. Regression analysis determined the impact of several parameters on wear rate, whilst machine learning approaches expanded the evaluation of wear rate and coefficient of friction beyond experimental data. The findings demonstrate the effectiveness of combining Taguchi methods with machine learning to accurately anticipate wear mechanisms in Ni-Cu alloy composites.

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.

Experimental Study on Dry Milling of Stir-Casted and Heat-Treated Mg-Gd-Y-Er Alloy Using TOPSIS

This study examines the dry milling process of a rare-earth-based magnesium alloy, emphasizing the optimization of the milling parameters and their impact on the surface quality, cutting forces, and the rate of material removal. The objective is to improve our comprehension of the milling behavior of the Mg-Gd-Y-Er alloy. The Taguchi technique is adopted to formulate the experimental design. This study methodically investigates the influence of heat treatment (T4 and T6) on milling performance, and the effects of speed, feed rate, and depth of cut. The output variables considered for this investigation are the surface roughness (Ra, Rz, Sa, and Sz), material removal rate (MRR), and cutting force. To optimize the milling parameters and achieve superior outcomes, the multi-objective optimization technique TOPSIS is used. At a feed rate of 150 mm/min, a spindle speed of 1500 rpm, and a depth of cut of 1 mm, the T4-treated sample exhibits a minimum surface roughness value of 0.0305 µm. The highest resultant force values of 96.4416 N and 176.1070 N for 200 °C and 225 °C T6-treated alloys are obtained by combining process parameters such as a spindle speed of 1500 rpm, a feed rate of 50 mm/min, and a depth of cut of 1.5 mm. Furthermore, the maximum closeness coefficient value is achieved by combining a spindle speed of 1000 to 1500 rpm, a feed rate of 150 mm/min, and a depth of cut of 0.5 mm to 1 mm. The closeness coefficient value is significantly influenced by the most significant process parameters, as indicated by the ANOVA results.

Enhancing the machining productivity in PMEDM for titanium alloy with low-frequency vibrations associated with the workpiece

Abstract The incorporation of frequency vibration into the powder mixed electric discharge machining (PMEDM) process has the potential to significantly enhance the productivity and quality of the machining process, as well as to provide a great deal of opportunities in this sector. An analysis and evaluation of the machining productivity (material removal rate [MRR]) in PMEDM with low-frequency vibration was carried out in this work by considering SKD61 as a workpiece. The oil dielectric solution mixed with titanium powder was used as a dielectric medium with red copper (Cu) as the electrode. At this point in time, the process technology parameters that have been chosen for inquiry are as follows: current (I), pulse on time (T on), powder concentration (C p), P, F, and A. The Taguchi technique (L25) was used to create the experimental matrix. With the use of analysis of variance, it was able to examine the impact that the factors had on MRR, and the analysis was utilized to ascertain the highest possible value of MRR. I was the parameter that has the most significant effect, according to the findings, whereas T on was the parameter that has the least significant effect. The maximum value of the MRRmax is equal to 31.29 mm3/min.

Comparative study: High performance polymers of polyphenylene sulfide and polyethylenimine using Taguchi-Topsis optimization approaches

The role of high-performance thermoplastic products is increasing in the present days because of its excellent physical and mechanical properties and also capable of withstanding critical loads and temperatures. In this study, an attempt was made to improve the mechanical and physical properties of two polymers PPS (Polyphenylene Sulfide) and PEI (Polyethylenimine) by addition of glass fiber as a reinforcement fiber. The glass fiber (GF) content considered as 40 wt% for both the polymers. Injection molding method was used for fabrication of PPS and PEI samples. After fabrication, mechanical tests such as tensile, impact and dimensional shrinkage (%) of samples were calculated. Taguchi and Topsis analysis techniques were applied for evaluation of major influencing parameters and determining the best experiment to be performed on the machine. After conducting the test, PPS polymer exhibited better mechanical strength values and lower shrinkage (%) compared to PEI. The best input parameters kept on the machine were observed to be gate way type, temperature and pressure. The conditions of gate way type 2, temperature 320°C, and a pressure of 100 bar are obtained as the best input parameters to be fixed on the machine for achieving higher values of mechanical strength and lower dimensional shrinkage for both PPS and PEI polymers. Out of these two polymers, PPS exhibited better mechanical and physical properties combining with GF. This polymer can extend its usage as a high-performance polymer for various industrial applications.

An experimental investigation of the performance of cross-flow turbine: impact of number of blades in runner

ABSTRACT This study examines a cross-flow turbomachine designed for power generation in areas with limited discharge and head availability, focusing on sustainability, affordability, and ease of operation. It investigates how varying the number of blades in the runner affects turbine performance while keeping other design factors constant. Testing runners with 8, 12, 16, 20, and 24 blades under identical conditions reveal consistent RPM variations across different blade numbers for various parameter combinations. The study identifies a 12-blade configuration as optimal for electrification projects at selected sites. Experimental validation using the Taguchi technique confirms the reliability of the findings. Additionally, the research explores the turbine’s performance under different nozzle tip elevations (18 cm, 16 cm, and 14 cm). The highest observed runner speed is 345 RPM for the 12-blade runner at an 8° angle of attack, with similar speeds recorded for the 24-blade runner under similar conditions.

Power performance enhancement for a three-turbine cluster of two-stage Savonius rotors using Taguchi approach

Choosing an optimal Savonius vertical-axis wind turbine (VAWT) arrangement that delivers the largest power coefficient is a significant challenge. So, in this paper, an optimization of the power performance using the Taguchi technique is presented for a three-turbine cluster of two-stage Savonius rotors. A three-dimensional, unsteady, incompressible airflow model is numerically solved using ANSYS and validated using published experimental and numerical studies. The power performance of the three VAWTs is optimized by adjusting five factors, including the relative angles between the turbines (ϕ12 and ϕ13), the rotation directions (RD), and the turbine spacings (S12 and S13). The rated power coefficient (CP) and its corresponding Tip Speed Ratio (TSR) are numerically obtained for an L16 (45) orthogonal array (OA). After the signal-to-noise ratio analysis, the optimal case is obtained. Results indicate that the configuration angles have the main effect on CP, the turbine spacing between the first and second rotors and the combination of rotation directions have the lowest effect. The optimal case is found to be (S12 = 2D, S13 = 2.4D, ϕ12 = ϕ13 = 70⁰, and RD = -, +, -), resulting in an increase of 19.69 % in CP compared to the isolated turbine at a rated TSR of 0.8.

Analysis of thermo-hydraulic flow and optimisation heat augmentation in 3D dimpled pipe based on design of experiment method and Taguchi technique evaluation

In this work, the numerical analysis concentrates on investigating thermal flow patterns, pressure drops, varying velocity components and heat transfer behaviour. Impacts of four parameters on the enhancement of thermohydraulic performance are carried out using three-dimensional calculations employing CFD techniques: different spacing, diameter, number and distance for dimples were investigated. Additionally, utilising a design of experiments (DoE) strategy together with the Taguchi technique (TT) and response surface methodology (RSM), the impacts of the factors listed below are optimised. The results indicated that the different flow fields and heat transfer patterns were because of the use of depressions on the tube's inner surface. A comprehensive flow investigation with the dimple and tube wall was established to explain the mechanism of pressure drop and heat transfer change. The results of orthogonal experiments show that the optimal design of the spiral tube in this investigation using computational fluid dynamics using DoE, RSM and TT has a temperature difference and heat transfer coefficient of about 35.75% and 36.1% higher improved pipes. The results show a high PEF value greater than 1. According to the above results, various design applications require flow hydrodynamic analysis and heat performance enhancement.