Taguchi Technique Research Articles

Optimal Constrained Groove Pressing Process Parameters Applying Modified Taguchi Technique and Multi-Objective Optimization

Most engineering problems are complicated, and developing mathematical models for such problems requires understanding the phenomena through experiments. It is well known that as processing parameters with assigned levels increase, so does the number of experiments. By minimizing the number of experiments, Taguchi’s method of experimental design will help to furnish the idea of full factorial experimental design. Taguchi’s method is more appropriate for single-objective optimization problems and needs modifications while dealing with multi-objective optimization problems. Aluminum alloys are in great demand in today’s automotive and aerospace sectors due to their low density, good corrosion resistance, and excellent machinability. The material is subjected to a constrained groove pressing (CGP) process to obtain microstructural grain refinement with enhanced mechanical behavior. This paper considers AA6061 material having major alloys such as silicon and magnesium. For this work, 3 CGP process parameters (viz., displacement rate, plate thickness and number of passes) are assigned 3 levels to each parameter, acquired the test data, viz., grain size (gs), micro hardness (hs), and tensile strength (ult) based on L9 orthogonal array of Taguchi. Using a modified version of Taguchi’s methodology, it is possible to estimate the range of grain size (gs), micro hardness (hs), and tensile strength (σult) for effective combinations of the CGP processing parameters and validate the results with existing test data. A more dependable and simpler multi-objective optimization procedure is used to choose the optimal CGP processing parameters.

Optimizing the crashworthy behaviors of hybrid composite structures through Taguchi approach

AbstractThis paper calculates the crashworthiness capability of glass‐reinforced epoxy composites over wrapped polyvinyl chloride (PVC) circular tubes with a triggering mechanism in the form of cutouts. The intended tubes were prepared by a wet wrapping method; after which they were subjected to quasi‐static axial compression. To compute crashworthiness indications, three design parameters, each at three levels, were used. The design parameters are the hole diameter (d), the hole's number (n), and the hole position (L). The Taguchi technique has been employed in the design of experiments (DOE) tactic to obtain the best crashworthiness parameters. With the maximum specific energy absorbed (SEA) and crashing force efficiency (CFE), the optimal parameters were found. Furthermore, the main effect, signal‐to‐noise ratio (S/N), as well as the analysis of variance (ANOVA), have been studied using the commercial software programme MINITAB 18. A few experiments were accompanied by the L9 orthogonal array. According to the results, “N” has the largest impact on the value of SEA with a contribution percent of 29.27%. While “d” has the main influence on the value of CFE with a contribution percent of 67.29%. Lastly, tests for confirmation were performed. to verify the predicted values in light of the experimental results. The optimized SEA developed tube is 74.72%, which is higher than the intact PVC tube and 12.29% lower than the intact hybrid tube. However, the optimum CFE was also 48 and 29.82% higher than the intact PVC tube and the intact hybrid tube, respectively.Highlights The number of holes has the highest impact on SEA value by 29%. The ideal specimen enhances SEA by 75% compared to the intact PVC tube. Hole diameter has the most influence on CFE value by 67%. The best specimen improves the CFE by 48% related to the intact PVC tube.

Experimental investigation and optimization of process parameters on digital light processing (DLP) 3D printing process based on Taguchi-grey relational analysis

Additive manufacturing technology, specifically Digital Light Processing (DLP), offers a unique approach to fabricating intricate objects without the need for traditional molds or machining. The technique described entails the incremental construction of layers through the curing process polymer, facilitated by a projection light source. Digital Light Processing 3D printing is particularly suited for creating complex structures with small cross-sections, requiring high surface polish and durability. In this study, DLP-printed test coupons were produced using an Ultraviolet-sensitive resin, and the investigation focused on examining the impact of surface quality and toughness, adhering to guidelines outlined by the ASTM specifications. To optimize the DLP printing process, Taguchi and Grey relational optimization techniques were employed to find the best values for multiple factors. The parameters considered in this study were speed, layer thickness, orientation, and pattern type. By employing these techniques, the optimal parameters were identified as follows: The printing process is conducted at a speed of 3 mm per second, with each layer being 0.05 mm thick and the orientation of the printed object is set at 90 degrees, and the pattern employed is of the square type. Experimental results revealed that utilizing these parameters yielded a surface roughness of 2.58 µm and an impact strength of 9.1J. The results showed that the Grey relational grade improved from 0.6244 to 0.7974, with a deviation of 0.173 and 27.71%, indicating a significant enhancement in the optimization process. Additionally, contour plots depicting the relationships between speed and orientation, speed and layer thickness, and orientation and layer thickness were generated for surface roughness, impact strength, and the Grey relational grade. This research offers valuable insights into optimizing DLP 3D printing processes to achieve enhanced surface quality, toughness, and material efficiency while reducing costs and production time.

Synthesis and Investigation on Mechanical Properties of Hybrid FRP Composite Using Taguchi Technique

Synthesis and Investigation on Mechanical Properties of Hybrid FRP Composite Using Taguchi Technique

THE APPLICATION OF THE TAGUCHI METHOD FOR OPTIMIZING THE COMPRESSION STRENGTH OF PLA SAMPLES PRODUCED USING FDM

In this study, the Taguchi method was applied to optimize the compressive strength of PLA samples produced using Fused Deposition Modelling (FDM). The study used Taguchi L9 experimental design to optimize three different process parameters (wall thickness, filling pattern, and printing speed). S/N ratios and ANOVA methods were used to analyze the experiments. The results of the experiments using the Taguchi technique were analyzed according to S/N ratios and the parameter levels with the best results were determined. The best levels for wall thickness, filling pattern, and print speed parameters were determined and the effects of these parameters were analyzed. It was concluded that wall thickness was the most effective parameter and filling pattern and print speed were less effective. ANOVA analysis confirmed the influence of the parameters on the compressive strength. It was observed that wall thickness contributed the most (70.20%) and filling pattern contributed the second most (29.11%).

Optimization on stir casting process parameters of Al7050 based composites using Taguchi technique

Aluminium Alloy Metal Matrix Composites (AAMMCs) are broadly used for various applications such as aerospace, military, marine, transport and automobile applications. Aluminium alloys are not sufficient for satisfying the needs of the fastest growing industries. The more combination of properties are needed for fulfil the need of fastest growing countries. The input process parameters of fabrication methods of composites are more important in connection with mechanical and tribological properties. In this research, optimization on stir casting input process parameters of AA7050/4wt.%WC composite was done by utilizing the Taguchi technique. The melting temperature (650, 700 and 750 °C), stirring speed (150, 200 and 250 rpm) and stirring duration (10, 20 and 30 min)were selected as input parameters to optimize the stir casting input process parameters. The chosen response parameter for the investigation was wear loss. The wear test was conducted by using pin on disc setup at the condition of 2500 m sliding distance, 25 N applied load and 1.5 m/s sliding velocity. The optimized input process parameters of stir casting is high level of melting temperature (750 °C), low level of stirring speed (150 rpm) and low level of stirring duration (10 min). The increasing of melting temperature decreases the wear loss and increasing of stirring duration and stirring speed enhances the wear loss due to accumulation of reinforcements in the matrix AA7050. The contribution percentage of melting temperature, stirring speed and stirring duration is 81.02 %, 12.4 % and 6.4 % respectively. The high strength MgZn2 precipitate was formed while using optimized stirring temperature, stirring duration and stirring speed and it was confirmed by XRD. The SEM image of AA7050/4wt.%WC confirmed that uniform distribution of WC in matrix AA7050 material and it caused to offer higher wear resistance. The obtained low wear loss for confirmation test specimen is 16 mg.

Optimization of wire electrical discharge machining parameters of AA6063/Al2O3 nanocomposite processed by multi axial forging using Taguchi technique

AbstractThe aluminium based matrix composites have excellent mechanical properties to use in automobile, aerospace, aviation, and military industries. The aluminium based matrix composite possesses desired characteristics like specific strength, excellent rigidity and wear resistance. The stir casting technique was used to fabricate the nanocomposite of AA6063 alloy reinforced with 5 weight % nano aluminium oxide particulate. To improve the microhardness of as cast and aluminium based nanocomposites, multiaxial forging was performed up to three passes for grain refinement. Wire electrical discharge machining was used to machine both as cast and “AA6063/Al2O3” (zero and three multi axial forging pass). The machining characteristics of samples were statistically examined using the Taguchi technique. The material removal rate in three multiaxial forging pass nanocomposite sample increased as peak current increases. However, increasing the pulse off time resulted in the lowest material removal rate. The surface roughness was found to be higher in the nanocomposite sample in comparison to as cast. The machining on nanocomposite multiaxial forged sample has a greater impact as compared to as cast. After machining, scanning electron microscopy was used to examine the surface morphology. The presence of different elements in the castings was validated using energy dispersive X‐ray spectroscopy.

Analysis and optimisation of emissions and fuel economy of biodiesel fuelled CI engine using Taguchi technique

The objectives of the present work are to examine the combined effect of engine operating and injection parameters and to optimise these parameters for better fuel economy, performance, and reduced emissions. The fuels used were diesel and biodiesel blends of Jatropha and Karanja biodiesel. The results indicate that diesel gives higher thermal efficiency at low loads, however, the 20% jatropha blend was slightly more efficient, at high loads. It was observed that the BSFC increases when the EGR is varied from 0% to 20%. Even though the smoke opacity increases with increased EGR, advanced injection at 28o BTDC decreases smoke. Increased EGR also reduced NOx emissions by up to 11%. Blending also has a significant impact on the output parameters. Taguchi analysis was applied to optimise the performance and emission characteristics of the diesel engine and set of input values were obtained for the optimum performance under different conditions.

Optimization of Core Loss for Power Transformer Using Taguchi Method

This article focuses on the optimization of process parameters such as core area, core material and voltage for the design of power transformer. It employs Taguchi orthogonal array technique for designing the experiments and its analysis. Utility transformers are usually specified with the losses associated at design stage. The area of the core cross-section applied voltage, as well as the core material all has impact core loss deterioration. The impact of such variables influencing core loss is investigated by executing the model. A small proportion of core as well as the coil assembly experiments is simulated using the Taguchi approach with the orthogonal array. In this study, the core as well as the coil assembly of an 8MVA, 33/11KV, 3 Phase Transformer is modelled in ANSYS MAXWELL software. MINITAB software is used to assess the program's anticipated core loss in order to discover the optimal arrangement for three control variables.

Prediction of weld bead geometry of AA5083 using taguchi technique: in the presence of siliconized zn-graphene oxide complex nanoparticles

Prediction of weld bead geometry of AA5083 using taguchi technique: in the presence of siliconized zn-graphene oxide complex nanoparticles

Analysis of a novel high-speed homogenizer technique for methyl ester production using waste cooking oil: Multi-objective optimization and energy analysis

While fossil fuels continue to be the predominant energy source, the use of renewable energy is consistently growing. Biodiesel, with its various advantages over traditional fossil fuels, stands out as a promising alternative fuel that is produced from a sustainable and abundant waste cooking oil (WCO) via a transesterification reaction (due to the low acid value of WCO) with alcohol (MeOH) and homogeneous catalyst (KOH) in a high-speed homogenizer. Biodiesel is produced in the industry using conventional mechanical stirring techniques, which are time-consuming and less efficient. It has been recently reported that high-speed homogenizers have the scale-up potential as per industrial requirements and can significantly reduce the transesterification/esterification reaction time. In the present investigation, the Taguchi technique has been applied for the design of experiments and multi-response process optimization using a composite desirability approach. The optimized values observed for yield, yield efficiency, and pour point were 99.18 ± 0.2%, 5.4 × 10–3 g/J, and − 14.9 ± 0.5 °C, respectively, at alcohol to oil molar proportion of 7:1, KOH amount of 0.5 wt%, rotor speed of 14000 rpm and 10 min of process time. The physicochemical properties of produced biodiesel were found within EN 14214 and ASTM D6751 standards limits.

Design and optimization of phase frequency detector through Taguchi and ANOVA statistical techniques for fast settling low power frequency synthesizer

In this work, a novel phase frequency detector (PFD) architecture using pass transistor logic is proposed. The circuit does not have a reset path, resulting in the elimination of blind zone and dead zone. The ϕ-V characteristics of the PFD were found to have better linearity across the range of −π to π due to the absence of blind and dead zones. The Taguchi and ANOVA statistical techniques were used to optimize the PFD. The optimized PFD exhibited a phase noise of −142.24 dBc/Hz, consumed 5.64 μW of power and had a maximum operating frequency of 5.25 GHz, and a delay of 10.65 ps. Using this PFD, a GHz-range synthesizer was designed, and its performance characteristics were obtained from circuit simulations using CADENCE Virtuoso. The synthesizer had a power consumption of 4.25 mW at a supply of 1.8 V, achieved a lock time of 2.95μs, and could generate frequencies ranging from 0.1 GHz to 4.75 GHz while occupying a chip area of 0.013 mm2. Moreover, the work introduced a new figure of merit, FoM. The synthesizer has potential applications in various devices such as radio receivers, televisions, mobile phones, satellite receivers, and GPS systems.

OPTIMIZING SHRINKAGE DEFECTS IN GREY CAST IRON BUTTERFLY VALVE CASTING: A SIMULATION AND EXPERIMENT-BASED APPROACH

The study focused on addressing casting defects in green sand casting that have negatively impacted the quality of the butterfly valve body. By employing various methods such as observation, interviews, numerical experimentation, and simulation, the researchers aimed to develop and evaluate a sand-casting technique for the butterfly valve body. Solidworks software was used to model the component and its gating system, while ProCAST software enabled mold filling and solidification analyses. The goal was to minimize shrinkage porosities in the cast butterfly valve body by optimizing process parameters through numerical experiments and the Taguchi technique. Analysis of variance (ANOVA) using Minitab 18 software analyzed the results. Through this research, the sand mold-related defect was reduced from 10% to 3%, and the special shrinkage defect was reduced from 26% to 2% by using a simulation of casting.

Optimization of a Two-stage Bevel Helical Gearbox using Multiple Objectives to Increase Efficiency and Reduce Gearbox Bottom Area

This study aims to look at multi-target optimization of two-stage bevel helical gearboxes to determine the best major design factors for reducing gearbox bottom area (GBA) and increasing gearbox efficiency (GE). Grey relation analysis (GRA) and the Taguchi technique were used to address the problem in two steps. Prioritizing the closure of the variable level gap, the single-objective optimization problem was addressed, followed by the multi-objective optimization problem, which identified the ideal primary design variables. Additionally, the first-stage gear ratio, allowable contact stresses (ACS), and first and second-stage coefficients of wheel face width (CWFW) were calculated. The outcomes of the study were used to determine the best values for five essential design features of a two-stage bevel helical gearbox (BHG).

Coating Performance Prediction using a Modified Spin Coater and the Taguchi Technique for Solar Cells

Background:: This paper presents a novel approach to enhance the efficiency of solar cells by employing a modified spin coating technique with a Zinc oxide (ZnO) solution. Spin coating, known for its ability to achieve uniform, thin coatings on flat to moderately curved surfaces, serves as the central method in this research. The study meticulously investigates various factors affecting the coating process, including the volume of the solution, spinning speed, and spinning duration. To optimize these factors effectively, the Taguchi approach is employed, aiming to achieve the desired ZnO layer thickness and uniformity. The experimental findings reveal that the most favorable results are obtained when implementing a 3-second spin cycle at a rapid spin speed of 2000 rpm while using a ZnO solution volume of 5 microliters. Furthermore, advanced techniques such as scanning electron microscopy (SEM) are harnessed to scrutinize the surface characteristics of the ZnO layer and its interaction with the solution. To gauge the quality of the coatings, the signal-tonoise ratio (SNR) main impact plot is thoughtfully utilized. Subsequent in-depth analysis, employing the analysis of variance (ANOVA) technique, delves into the intricate relationship between the experimental parameters and the response parameter. The research outcomes are nothing short of remarkable, showcasing that the modified spin coating technique significantly elevates the efficiency of coated solar cells, ultimately achieving an impressive efficiency rate of 5.4%. In summation, this study introduces a pioneering spin coating technique tailored for solar cell applications with ZnO solution, leading to substantial enhancements in efficiency. The thorough optimization of process parameters through the Taguchi technique, coupled with the comprehensive analysis of experimental results via ANOVA, not only advances the comprehension of the coating process but also paves the way for more efficient and sustainable solar cell applications in the future. Methods:: The research systematically explored critical factors affecting the coating process for solar cells, optimizing the ZnO layer's thickness and uniformity. The ideal parameters identified were a 3-second spin cycle at 2000 rpm with a ZnO solution volume of 5 microliters. Quality assessment was done using the signal-to-noise ratio (SNR) main impact plot, and further analysis via ANOVA revealed intricate parameter relationships. These findings offer a precise and efficient method for improving solar cell coatings, promising enhanced efficiency in renewable energy production. Results:: The research achieved a minimum film thickness of 4.2 micrometers and revealed a correlation between spinning speed and film thickness. Solar cell efficiency reached an impressive 5.4% post-ZnO coating. The modified spin coating device outperformed conventional methods, enhancing efficiency by 5% to 10%. These results signify a significant breakthrough in improving solar cell performance and hold promise for more efficient solar energy production. Conclusion:: This research optimized the spin coating process to apply ZnO solution to solar cells, achieving the desired film thickness. Ideal parameters were found: 2000 rpm spinning speed, three seconds spinning duration, and four microliters of solution. This resulted in a minimum film thickness of 4.2 micrometers. Higher spinning speeds correlated with thinner films, as shown in a contour plot. Solar cell efficiency reached 5.4% after the ZnO coating. A redesigned spin coating device outperformed conventional methods, improving efficiency by 5% to 10%. This modified technique holds promise for more efficient solar panel production.

Application of machine learning and grey Taguchi technique for the development and optimization of a natural fiber hybrid reinforced polymer composite for aircraft body manufacture

Abstract The rapid expansion of the air transport industry raises significant sustainability concerns due to its substantial carbon emissions and contribution to global climate change. These emissions are closely linked to fuel consumption, which in turn is influenced by the weight of materials used in aircraft systems. This study extensively applied machine learning tools for the optimization of natural fiber-reinforced composite material production parameters for aircraft body application. The Taguchi optimization technique was used to study the effect of sisal fibers, glass fibers, fiber length, and NaOH treatment concentration on the performance of the materials. Multi-objective optimization methods like the grey relational analysis and genetic algorithm (using the MATLAB programming interface) were employed to obtain the best combination of the studied factors for low fuel consumption (low carbon emission) and high-reliability structural applications of aircraft. The models developed from regressional analysis had high accuracy of prediction, with R-Square values all >80%. Optimization of the grey relational analysis of the developed composite using the genetic algorithm showed the best process parameter to achieve low weight material for aircraft application to be 40% sisal, 5% glass fiber at 35 mm fiber length, and 5% NaOH concentration with grey relational analysis at the highest possible level, which is unity.

Application of Taguchi Technique and Grey Relational Analysis for Multi-Target Optimization of Two-stage Helical Gearboxes

Application of Taguchi Technique and Grey Relational Analysis for Multi-Target Optimization of Two-stage Helical Gearboxes

Taguchi's Technique for Optimising FSPCM Parameters for Drying Application

Taguchi's Technique for Optimising FSPCM Parameters for Drying Application

Optimizing the Synthesis of Novel Calcium Carbonate/Cobalt Oxide Nanocomposite With Highest Antifungal Activity

Today, the rise of opportunistic infections and their resistance to current antifungal drugs has led to the inevitable need to produce effective antimicrobials at a reasonable cost. This study aimed at producing a calcium carbonate/cobalt oxide nanocomposite with the most excellent antifungal activity against Candida albicans (C. albicans). Thus, nine experimental designs using the Taguchi technique were utilized to discover the greatest combination of parameters for antifungal activity. The colony‐forming unit (CFU) method was used to test the produced nanocomposites’ antifungal properties against C. albicans. The results indicated that the synthesized nanocomposite in optimal conditions (20 mg/mL of calcium carbonate, 3 mg/mL of cobalt oxide, and 90 min of stirring time) could inhibit the growth of C. albicans by more than 74%. Various analyses were applied to determine the structural properties of the calcium carbonate/cobalt oxide nanocomposite, and its constituents revealed the fabricated nanocomposite’s desirable properties. In the study, the nanocomposite was an efficient antifungal agent that might be employed in various fields, including medicine, dentistry, and life sciences.

Optimization of welding parameters on weld deposits area in pulsed gas metal arc welding

This paper presents a methodology for optimising pulsed gas metal arc welding parameters on Stainless Steel GRADE 410. Most sectors favour the economic welding technique for its favourable outcomes, such as enhanced strength and reduced corrosion. Compared to conventional welding methods, pulsed gas metal arc welding has the advantage of reducing current consumption and increasing the rate at which metal is deposited. An optimisation technique is employed to forecast the weld bead's accurate geometry, penetration depth, and reinforcement height, considering the welding input parameters such as welding speed, current rate, and frequency level. The Taguchi technique uses experimental analysis by considering input and output parameters. A multiple regression analysis model has been developed for SS Grade 410 Stainless steel to determine the bead geometry's correctness.