Taguchi

The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.

Plastic Injection molding industry has been playing a major role in the mass production of plastic products for various industries; here a product from electrical industry is taken and studied for its quality improvement. This Study deals with the application of Computer-aided Engineering integrating with statistical technique to develop an injection molded Electrical Product with a reduced warpage and shrinkage which is considered as serious quality defects. For this purpose, the optimum injection molding processing parameters were found by conducting number of flow analyses using Moldex 3D software. The various combination of parameters were selected by following the L27 orthogonal array, the optimization methodology of Taguchi, experimental design and analysis of variance (ANOVA) were used to predict the optimum and significant process parameters inducing the warpage and shrinkage. Statically it is concluded that Packing Pressure and Melt temperature were found to be the most significant parameters, while the mold temperature had the least effect on the warpage and shrinkage for this product. Furthermore effect of variation of significant parameters on the warpage and shrinkage are also studied.

PD Bata Merah Top Abadi memproduksi bata merah dengan campuran tanah liat dan air dengan proses produksi secara konvensional (terkecuali penggilingan). Permasalahan pada proses produksi bata merah adalah masih terus menerus terdapat produk cacat setiap proses produksinya yang dapat merugikan para pengrajin bata merah serta kurangnya pengetahuan mengenai kuat tekan bata merah.  Tujuannya mengusulkan perbaikan kualitas bata merah untuk dapat meminimasi cacat produksi yang masih tinggi. Oleh karena itu, untuk mengidentifikasi dan upaya meningkatkan kualitas bata merah pada proses produksi bata merah maka diterapkannya metode Six Sigma. fase Define, Measure, Analyze, dan Improve. Pada fase improve kombinasi level optimal pada proses bata merah dengan menggunakan pendekatan metode Taguchi. Berdasarkan hasil analisis DMAI didapatkan 4 Critical To Quality yaitu bata merah hancur, bata merah retak, bata merah gopel dan bata merah gosong, serta didapatkan nilai rata-rata DPMO dan level sigma menghasilkan 645.714 (1,85 sigma). Berdasarkan perhitungan eksperimen yang dilakukan mendapatkan hasil eksperimen Taguchi yang dilakukan maka didapatkan hasil setting level optimal yaitu rasio komposisi bahan baku (75% rasio tanah liat: 25% abu tebu), lama waktu penggilingan 1 jam, lama waktu penjemuran 5 hari dan posisi pembakaran lapisan bawah.

Kata Kunci : CTQ, DPMO, Kualitas, Six Sigma, Taguchi.

In machining technologies, one of the most important criteria that is taken into consideration when evaluating the product quality is seen as surface roughness. In order to achieve the desired level of surface roughness of the machined part, the tool vibration should be decreased to minimum levels. In the machining process, the most important parameters affecting the surface roughness and vibration are cutting parameters such as depth of cut, feed rate, rotational speed, tool wear and overhang. To obtain better surface roughness must be optimized this important parameters. There are many artificial intelligence optimization tools to parameter optimization. In this study, it is aimed that to investigate relation between surface roughness and tool vibration at first. Besides that the effects of cutting parameters such as depth of cut, feed rate, spindle speed on surface roughness and optimization of all parameters for best product quality. The optimum parameter combination developed by using Taguchi Method was confirmed with the help of confirmation tests. As a result, with the help of optimization, the surface roughness and the tool vibration was reduced.

Membrane distillation (MD) is a developing thermally driven membrane desalination technology that has been applied in four different basic configurations. In membrane distillation, a hot, saline feed stream is passed over a hydrophobic membrane. The temperature difference between the two sides of the membrane leads to a vapour pressure difference that causes water vapour to permeate through the membrane pores, and then condensed on the cold side of the membrane. The hydrophobicity of the membrane prevents the liquid from passing through the pores, while the water vapour is allowed to pass through. The technique offers the attractiveness of operation at atmospheric pressure and low temperature (40– 90oC), and has the theoretical ability to achieve 100% salt rejection. Thus, low-grade energy like solar and waste energy can be used for desalination.
In this work, an experimental investigation of the performance of Air Gap Membrane Distillation (AGMD) system was performed for seawater and laboratory prepared salt feed water solutions. The influences of  system operating parameters such as feed temperature, feed flow rate, coolant temperature, coolant flow rate and air gap width on permeate flux were studied. The effects of membrane pore size as well as the concentration of feed solution on permeate flux were also investigated. The performance of the AGMD unit was statistically optimized using design of experiment (DOE) and Taguchi technique. Furthermore, theoretical model describing heat and mass transfer analysis in AGMD was developed and discussed in detail.
The permeate flux was found to increase with increasing feed temperature and feed flow rate. However, it decreased with increasing air gap width and coolant temperature. The system performance tends to increase marginally with increasing coolant flow rate. The system performance is mostly dominated by the effect of both feed temperature and air gap width. Feed flow rate and coolant temperature have relatively considerable effect on flux. Increasing the membrane pore size from PTFE 0.22µm to PTFE 0.45µm leads to about 10% increment in flux production. While increasing the feed concentration from 0.075g/L to 60g/L lead to about 11% drop in permeate flux. The tested double-stage AGMD design was capable of achieving a maximum permeate flux of 128.46kg/m2hr, which is almost twice that of single stage unit, under the same experimental conditions.
In general, the theoretical model results were found to be in good agreement with the experimental data as the maximum deviation of model results was within 15%. The model was also used to predict thermal efficiency and temperature polarization of the AGMD system.
Regarding system optimization using Taguchi methodology, the developed model proved to be in good agreement with the experimental data with a maximum deviation of about 10%. According to Taguchi orthogonal arrays, the experimental and model optimum system performance was found to be 76.0457 kg/m2h, and 74.5916 kg/m2h respectively. The conditions for the optimum performance are 80oC feed temperature, 5 L/min feed flow rate, air gap width of 3mm and coolant temperature of 20oC.

Ramor 500 zırh çeliği; 2-30 mm kalınlıklara sahip, 505-590 HV sertliklerde bulunan yüksek mukavemetli bir balistik koruma çeliği olarak sınıflandırılır. Aşınma, kayma yüzeyleri arasındaki mekanik etkinin etkisiyle yüzeyler üzerinde malzemenin deformasyonuna ve kaybına neden olan bir etkileşim işlemidir. Bu çalışmada, konstrüksiyon imalat sanayisinde kullanılan Ramor 500 çeliğinin ısıl işlem sonrası mikroyapı, mikrosertlik ve abrasiv aşınma direncine etkisinin taguchi metoduyla değerlendirilmesi ve etkileri incelenmiştir. Bu amaçla Ramor 500 çeliği 900 o C sıcaklıkta tavlanmış ve 3 faklı ortamda soğutulmuştur. İnceleme sonucunda mikroyapı ve mikrosertlik incelenmiştir. Ayrıca ısıl işlemsiz numunelerle kıyaslamak maksadıyla abrasiv aşınma testine tabi tutulmuştur. Elde edilen veriler Taguchi metoduyla değerlendirilip Varyans analizleriyle seviye ve parametrelerin aşınmaya olan etkileri incelenmiştir. Yapılan ısıl işlemler sonrasında sertlik değerlerinde esas metalin altında kalınmıştır. Seçilen bütün parametrelerin aşınmaya etkisi olmuştur. Kütle kaybının kontrol faktörleri üzerindeki etkisi countour plot renk dağılımı metoduyla gözlemlenmiştir.

Dry EDM is an environment-friendly modification of the oil based EDM process. In the current work, a unit has been developed to implement dry EDM process on existing oil based EDM machine. All experiments are performed on bright mild steel with the help of hollow copper electrode. Response variables analyzed are material removal rate, tool wear rate and surface roughness. Design of experiments is done using Taguchi method. All experiments are performed using process parameters such as current, pulse on time and oxygen gas pressure. The statistical analysis of results show that current and POT significantly influence MRR and TWR.

This paper presents complete process of turning operation by using CNC machine tool and the input parameters associated with the process that can be controlled to enhance the output quality parameters like material removal rate and average surface roughness as per the desired requirement. Every detail of turning operation and associated parameters is explained. The optimization techniques like Taguchi, Anova, S/N ratio, grey relational analysis is also described and their importance is also discussed in detail. The study explains step by step procedure involved in optimization of turning process in detail.

Injection moulding is the most common technique of plastic forming. The industry is usually referred to as a MIMO (multi-input-multi-output) process that is basically involved with several input parameters (control factors) yielding almost inconsistent results on output variables (response factors). As a result of this, product quality is a major challenge in such unstable manufacturing environment. Taguchi methods (TMs) are commonly used in plastic injection molding industry (PIMI) as a robust optimization technique to serve for a wide range application from product design optimization to mould design and from optimal material selection to processing parameter optimization. This paper primarily aims at providing a comprehensive chronological review and classification on different applications of TMs in PIMI to serve for the following two purposes: first to present an evolutionary trend of TMs in PIMI and second for a comparative capability analysis of TMs in selected industrial-based case studies. Major pros and cons of TMs in will also be highlighted as compared to other optimization techniques rather than Taguchi Method.

Complex geometries were laborious to machine in early times but with the emerging of advance machining technologies
incorporated with the process of chemical itching, electrical and mechanical machining is redefined. In present work, ECM is studied
with the end goal of optimizing the behaviour of process parameters viz, applied voltage, electrolyte concentration, IEG and electrolyte
flow rate on “Material Removal Rate” and “Radial Over Cut”. Taguchi (Orthogonal Array) based approach is applied for optimizing
several input factor and output responses in ECM. Taguchi Method studies variation in response parameter by applying signal to noise
“S/N” ratio. The quality characteristics of MRR are analysed briefly with concept of “Large the Better” and Radial overcut with
“Smaller the Better”. Minitab 17.0 software is utilized for calculating the values of S/N ratio. Further ANOVA test is conducted for
analysing the proposed hypothesis.

Door hinges are a key product in the automotive industry. The function of automotive door hinge is not only to close, open, and keep the open angle of the door but also to reduce traumas for passengers in the car when it is hit by another car. However, concentrated stress and strain occur at the corner of this product during forming, which can cause a crack if the shape of this area of the blank is not carefully designed. Accordingly, this article proposes a method for improving the press formability of a door hinge by changing the shape of the concerned area of the blank based on finite element method (FEM) simulations using the explicit dynamic code ABAQUS, version 6.5. The resulting optimized solution for robust forming was a corner radius of 7 mm, protrusion length of 18 mm, and protrusion height of 5 mm.

Al6061 with hard particle reinforcement contains higher stiffness, maximum strength and wear resistance when compare to unreinforced alloy. They can be usage for self-propelled automotive components and aircraft construction. Metal matrix composite (MMC) concentrate chiefly on amended specific strength and wear resistance application. Aluminium as base material and coconut shell ash(CSA) as reinforcement has good potential. The principle difficult is to create this composite in a practical manner. In this project Al6061-CSAp castings with different volume fraction of CSA were produced in an argon atmosphere by an enhanced stir casting method. We found that with more % of CSA addition there is an improvement in specific strength of the composite. Pin on disc equipment used for dry sliding wear analysis of MMCs. The Taguchi analysis revealed the improved specific strength as well as wear resistance. EDS analyses showed oxide phases presence in the castings. Surface Morphology particle distribution were examined in detail by SEM.

Quality is the prime requirement for most of the customers and hence it is always a challenging and upcoming task in industries. This work focus on Surface Roughness produced in hard turning process on Lathe. The process of hard turning is done on AISI 1040 Steel material under dry conditions using coated Carbide Inserts and High Speed Steel (HSS) Tools. Spindle Speed and Feed are chosen as control factors. The control factors are adopted to analyze significance and contribution on the Surface Roughness of the machined parts.
Taguchi methodology based on Orthogonal Arrays (OA) is used to Design the Experiments. Signal-to-noise Ratio (S/N ratio) of the generated Roughness values is used to evaluate the optimal machining parameter combinations. Later Analysis of Variance (ANOVA) is used to analyze the influences and contribution of the machining parameters on the Roughness values based on F-Statistic Test.
Regression Model analysis was developed for predicting the Average Surface Roughness (Ra) as a function of Speed and Feed. Confirmation experiments are yielding an error of max 8.55% and 0.46% in Regression, while machining with Carbide and HSS tools respectively.

This paper introduces the Taguchi optimization method to optimize the machining parameters of Nimonic 75 by CNC end milling. Taguchi analysis aids to know, the influence of machining parameters on results like surface roughness. CNC milling is the flexible process for material removing. Desired complex shapes can be produced by using CNC mill. It is fully automated, gives highly precision dimensions and surface finish.  Nimonic 75 is a special grade heat resistant nickel based super alloy. It has wide range of applications in aerospace, chemical, marine, furnaces, heat exchangers equipments etc due to its extreme capability to withstand at extreme temperature, pressure and corrosion. In the present work, the end milling of Nimonic 75 is carried to analysis by means of Taguchi method with the help of software MINITAB 14.0. The experimentation is done by means of Taguchi orthogonal array L27(33), 27 trials . Here input parameters are spindle speed (s), feed (f) and depth of cut (d), output response is average surface roughness Ra (µm).

Gas tungsten arc welding is a fusion welding process having broad application in industry. In this experiment selected three process parameters like current, groove angle and welding speed and range was decide for each parameters by trial and error method and distortion was the output parameters. To perform the experiment on TIG welding L27 orthogonal array has been used and based on that according to each run set experiment has performed and optimization run set was found. By Taguchi analysis and also find the regression equation for same experiment.

C and 70° C and air velocities of 0.5, 1, and 1.5 m/s, for the samples with particle sizes of 1.18 and 2mm (meshes of 16 and 10) and pellet diameters of 6 and 8 mm. The Taguchi quality engineering method was used to investigate the effects of the parameters on compressive strength of pellet. The orthogonal array, signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were employed to analyze the effect of the parameters on compressive strength. The optimal performance for the compressive strength of pellet was obtained at first level of factor A, i.e. the particle size of 1.18 mm, air temperature of 70"°

Gas metal arc welding (GMAW) process is most widely used in industries for fabrication works, due to higher productivity. The weld quality depends on the process parameters of GMAW. This research investigates the influence of process parameters af ecting the mechanical properties of weldment. Thus, identification of the GMWA process parameters that significantly af ect the quality of GMWA processed parts is more important in terms of productivity. Then process environment has been assumed consisting of four variables like welding current, welding voltage, shielding gas, gas flow rate and wire feed rate. Taguchi optimization technique has been applied to determine the optimal limits, which can maximize the GMWA quality in certain environment. Signal to noise ratio (S/N ratio) were calculated for each data and used to obtain the optimum level of every input parameter. The study also shows that the use of the Taguchi Method has productively enhanced on the existing process parameters.

Quality is the prime requirement for most of the customers and hence it is always a challenging and upcoming task in industries. This work focus on Surface Roughness produced in hard turning process on Lathe. The process of hard turning is done on AISI 1040 Steel material under dry conditions using coated Carbide Inserts and High Speed Steel (HSS) Tools. Spindle Speed and Feed are chosen as control factors. The control factors are adopted to analyze significance and contribution on the Surface Roughness of the machined parts. Taguchi methodology based on Orthogonal Arrays (OA) is used to Design the Experiments. Signal-to-noise Ratio (S/N ratio) of the generated Roughness values is used to evaluate the optimal machining parameter combinations. Later Analysis of Variance (ANOVA) is used to analyze the influences and contribution of the machining parameters on the Roughness values based on F-Statistic Test. Regression Model analysis was developed for predicting the Average Surface Roug...

In this study, the effects of cutting speed, feed rate, work piece hardness and depth of cut on surface roughness and tool tip temperature in the hard turning were experimentally investigated. AISI H11 (X38CrMoV5-1) steel was hardened to (40; 45 and 50) HRC, machined using cubic boron nitride (CBN 7025 from Sandvik Company) which is essentially made of 60% CBN. L27 orthogonal array based Taguchi optimization technique is used to optimize the effect of various cutting parameter for surface roughness and tool tip temperature of H11 work material in turning operation. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) are to be employed to analyze the effects and contributions of cutting parameter on the response variables. Attempt was further made to simultaneously optimize the machining parameters using Grey relational analysis. The feed rate is the most significant factor for minimize both surface roughness and tool tip temperature. The surface roughness was measured using surface roughness tester (Mitutoyo surftest-SJ210). Tool tip temperature was measured using Optex Thermo Hunter.

In this paper, cutting forces and expended energy which generated in the process of cutting the scrap bars are investigated an experimental study. Parameters affecting the cutting force is defined as cutting speed, the clearance, the cutting tool the radius, the cutting edge length and the bar diameters. In contrast to the preexisting studies is aimed to reduce the cutting forces and expended energy rather than the improvement of the cutting surface in this study. Three different levels of all five parameters are identified as variables. The number of experiments increases proportionally with the number of parameters. In order to use more parameters and perform fewer the number of experiments, this study is designed based on Taguchi L27 orthogonal array. The effect of these parameters which influence the cutting force on result is identified through variance analysis (ANOVA). As a result, the appropriate the cutting parameters are found by implementing verification tests.

In this study, effects on thrust force and burr height of the cutting parameters were experimentally investigated with uncoated and TiN coated HSS drills in drilling of Al-5083 alloy. The experiments were made by using Taguchi L 9 (3 3) the orthogonal experimental setup, with 8 mm diameter of HSS drill, three different spindle speeds (400-800-1200 rev / min), feed rates (0.1-0.2-0.3 mm / rev) and point angles (90-118-135 °). As a result of experiments, it is determined that the burr height increased with increasing spindle speed and the thrust force reduced. It is found that thrust force and burr height increased with increasing feed rate. When drilling with uncoated HSS drills, thrust forces and burr height were lesser than drilling with TiN coated drills. According to the analysis of variance (ANOVA), feed parameter among the independent variables is the most influential factor on thrust force and burr height, followed spindle speed and drill point angle, respectively. As a result of validation experiments it was found that the optimization studies was successfully resulted.

Taguchi methodology was implemented to optimize and evaluate the effect of process parameters such as the applied pressure and time of holding on the tribological properties of ultra-high molecular weight polyethylene (UHMWPE) nanocomposite reinforced with different loadings of silicon carbide (SiC) nanoparticles. An L 9 orthogonal array was used to design experimental matrix in terms of pressure, holding time, and the loading of SiC. UHMWPE/SiC nanocomposites were synthesized via ultrasonication and hot pressing. Pin on disk wear tests were carried out on the composites to evaluate the tribological properties such as specific wear rate and coefficient of friction. Friction and wear response were analyzed using analysis of variance and regression models. The effect of each parameter and optimal process parameters that result in minimum friction and specific wear rate were determined. The confirmation tests carried out verified the validity of the developed experimental design model.

Carbon nanotubes (CNTs), generated by rolling a layer of graphite into a seamless and hollow cylinder, can be divided into multi-walled carbon nanotubes (MWCNTs) and single-walled carbon nanotubes (SWCNTs) based on the numbers of carbon atom layers of the wall of the nanotubes. Since its discovery in 1991, CNTs have been the subject of numerous investigations in chemical, physical and materials areas due to their novel structural, mechanical, electronic, and chemical properties. The CNTs can be produced by different processes, such as arc-discharge, chemical vapor deposition (CV D) and laser ablation. In this study we synthesized CNTs by liquid arc discharge method along with a purification stage then a statistical design of experiments (DOE), Taguchi method (Qualitek4) was implemented to optimize experimental condition of this study. Voltage, current, catalyst and plasma were considered as process parameters to be optimized. As the result of taguchi analysis in this study, Voltage, current, catalyst were the most influencing parameters on the yield product of carbon Nanotubes. The maximum yield product of CNTs were obtained at 25v voltage, LiCI as a salt in solution, Ni/Mo as a catalyst and the ½ as a catalyst ratio (~6.89 mgr purred CNTs).