Abstract: Effect of turning parameters on chip generation during machining aluminum composite is studied in this work. Turning of Al–4%Cu–7.5%SiC composite material prepared through powder metallurgy procedure was chosen as the workpiece, machined using uncoated carbide insert TNMG 120404. Chips produced during machining were studied by measuring the thickness and were used along with uncut chip thickness to determine the chip thickness ratio. 99.85% pure aluminum was added with 4% volume fractions of copper and with silicon carbide particulates of 7.5%. To visualize the distribution of reinforcement phases in matrix, scanning electron microscope is used. Taguchi’s methodology of design of experiments was adopted for designing a L9 (Latin square) orthogonal array for experimental investigation, and from analysis of variance, cutting speed influencing the formation of chip by 64.13%, continuing with depth of cut by 35.26%, was identified. Confirmation test accomplished with ideal conditions produces a better chip condition.

Abstract: The aim of this paper is to process modelling of AWJM process on machining of green composites using fuzzy logic (FL). An integrated expert system comprising of Takagi–Sugeno–Kang (TSK) fuzzy model with subtractive clustering (SC) has been developed for prediction surface roughness in green AWJM. Initially, the data base is generated by performing the experiments on AWJM process using Taguchi $$(\hbox {L}_{27})$$ orthogonal array. Thereafter, SC is used to extracts the cluster information which are then utilized to construct the TSK model that best fit the data using minimum rules. The performance of TSK–FL model has been tested for its accuracy in prediction of surface roughness in AWJM process using artificially generated test cases. The result shows that, predictions through TSK–FL model are comparable with experimental results. The developed model can be used as systematic approach for prediction of surface roughness in green manufacturing processes.

Abstract: In the present work, the working of an electro discharge machining process was studied in which four factors, namely pulse on time, duty cycle, discharge current, and gap voltage, were considered to be the controllable parameters, each at three levels, for monitoring three responses, namely material removal rate, tool wear ratio, and tool overcut. Statistical design of experiments using Taguchi’s orthogonal array (OA) technique has been utilized to determine the optimum level of process parameters so that they are least affected by noise factors for obtaining a robust design of the parameters. Acknowledging the limitation that Taguchi’s OA technique can determine optimal setting of controllable parameters for one output or response at a time, integrated fuzzy AHP and fuzzy TOPSIS methods were used in the scheme of multi-response experiment so that Taguchi’s OA technique may be applied successfully for parametric optimization. The results show that none of the factors were highly significant although discharge current had the highest contribution (31.63%) among all.

Abstract: For the optimum design of a Porous Asphalt (PA) mixture, different requirements in terms of functionality and durability have to be fulfilled. In this research, the influence of different control factors such as binder type, fiber content, and binder content were statistically investigated in terms of multiple responses such as total air voids, interconnected air voids, particle loss in dry conditions, particle loss in wet conditions, and binder drainage. The experiments were conducted based on a Taguchi L18 orthogonal array. The best parametric combination per each response was analyzed through signal to noise ratio values. Multiple regression models were employed to predict the responses of the experiments. As more than one response is obtained, a multi-objective optimization was performed by employing Criteria Importance through Criteria Inter-Correlation (CRITIC) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) methodologies. The weights for the selection of the functional and mechanical performance criteria were derived from the CRITIC approach, whereas the ranking of the different experiments was obtained through the TOPSIS technique. According to the CRITIC-TOPSIS based Taguchi methodology, the optimal multiple-response was obtained for a polymer modified binder (PMB) with fiber and binder contents of 0.15% and 5.0%, respectively. In addition, good results were obtained when using a conventional 50/70 penetration grade binder with a 5.0% binder content and 0.05% fiber content.

Abstract: Surface roughness Ra is a parameter normally used to indicate the level of surface irregularities during machining operations. This work aims to model the cutting process, correlate and optimise the critical process parameters using the Taguchi method during the milling operation of AISI P20 in order to reduce surface roughness. The Autodesk Fusion 360 (2.0.5357) was employed for modelling the stress, displacement and thermal behaviour of the cutting tool and work piece under different cutting conditions. The experimental plan was based on Taguchi’s technique including L9 orthogonal array with three factors and three levels for each variable and studying the contribution of each factor on surface roughness. The Taguchi method was used to study the effect of process parameters and establish correlation among the cutting speed, feed and depth of cut with respect to the major machinability factor, surface finish. The machining parameters evaluated in this study are the depth of cut (d), spindle speed (N) and cutting feed (fm) while the response factor measured is surface roughness. The physical experiments were conducted on M200 TS material on a DMC 635 V DMG ECOLINE, Deckel Maho Germany, Siemens 810D, 3-Axis, CNC vertical milling machine using carbide inserts and the surface roughness was measured using the Mitutoyo SJ–201, surface roughness Machine. The statistical analysis of both the numerical and physical experiments brought about the development of a mathematical model and optimum solutions for the evaluation of surface roughness during the milling process with high degree of correlation with experimental values thus validating the developed model.

Abstract: The current work applies L9 (33) Orthogonal Array (OA) of Taguchi design to obtain an optimum combination of nature of fuel, speed of engine, and load for DI- CI diesel engine that is alternatively...

Abstract: The quality of welded joints developed using microwave hybrid heating (MHH) technique is largely influenced by properties of the constituents employed in the process. This article investigates the influence of process parameters on tensile strength and flexural strength of Inconel-625 plates welded through MHH. Experiments were planned according to Taguchi L16 orthogonal array by considering three factors: separator, susceptor and filler powder particle size. Ultimate tensile strength and flexural strength of the specimens welded at 600 and 900 W were chosen as response characteristics. Application of Taguchi-based GRA has been effectively used to optimize multi-performance characteristics of the process. ANOVA results indicate that size of interface filler powder is the most significant factor in determining the joint strength followed by separator and susceptor. Further to corroborate the optimal parameter setting for maximum strength values, metallurgical characterization of the specimens is carried out through XRD and SEM. Specimens processed at 600 W exhibited superior properties compared to their counterparts developed at 900 W.

Abstract: Purpose Scatter in the outcome of repeated experiments is unavoidable due to measurement errors in addition to the non-linear nature of the output responses with unknown influential input parameters. It is a standard practice to select an orthogonal array in the Taguchi approach for tracing optimum input parameters by conducting a few number of experiments and confirm them through additional experimentation (if necessary). The purpose of this paper is to present a simple methodology and its validation with existing test results in finding the expected range of the output response by suggesting modifications in the Taguchi method. Design/methodology/approach The modified Taguchi approach is proposed to find the optimum process parameters and the expected range of the output response. Findings This paper presents a simple methodology and its validation with existing test results in finding the expected range of the output response by suggesting modifications in the Taguchi method. Research limitations/implications Adequacy of this methodology should be examined by considering the test data on different materials and structures. Originality/value The introduction of Chauvenet’s criterion and opposing the signal-to-noise ratio transformation on repeated experiments of each test run will provide fruitful results and less computation burden.

Abstract: In this study, the effects of the process parameters on their performance characteristics of lead-induced Ti-6Al-4V alloy were investigated. Taguchi’s L27 orthogonal array (OA) has been used to con...

Abstract: The aim of this paper is to optimize the machining parameters to obtain the smallest average surface roughness values during drilling of the carbon fiber-reinforced polymer (CFRP) composite material with abrasive water jet (AWJ) and analyze the damage of the delamination.,CFRP composite material had been fabricated having fiber orientations frequently used in the aerospace industry (0°/45°/90°/−45°). Three different stand-off distances (1, 2 and 3 mm), three different water pressures (1,800, 2,800 and 3,800 bar) and three different hole diameters (4, 8 and 12 mm) were selected as processing parameters. The average surface roughness values were obtained, and delamination damage was then analyzed using Taguchi optimization. Drilling experiments were performed using the Taguchi L27 orthogonal array via Minitab 17 software. The signal/noise ratio was taken into account in the evaluation of the test results. Using the Taguchi method, the control factors giving the mean surface roughness values were determined. Analysis of variance was performed using the experimental results, and the effect levels of the control factors on the average surface roughness were found.,It was found that water pressure and hole diameter had a higher effect on average surface roughness, while water pressure and stand-off distance were effective on delamination.,Owing to their excellent thermal and mechanical properties, the CFRP composite materials show greater potential for their applications in aircraft and aerospace industry.,The novel approach is to reduce cost and spent time using Taguchi optimization as a result of AWJ drilling the material in this fiber orientation ([0°/45°/90°/−45°]s, which is often used in the aerospace industry).

Abstract: Strong orthogonal arrays have better space-filling properties than ordinary orthogonal arrays for computer experiments. We consider column-orthogonal strong orthogonal arrays of strength two plus and three minus, and present methods of constructing such designs. Several situations are examined, including those of four or higher levels and mixed levels. The methods are based on both regular and nonregular designs. The resulting designs inherit the good property of strong orthogonal arrays of strength two plus or three and have the additional property of column orthogonality. This type of design is a better choice for computer experiments.

Abstract: Porosity plays a vital role in the field of bio-medical engineering of implantations i.e. orthopedic and orthodontics. Shape memory alloys exhibit a greater strength with a higher porosity. The strength of porous shape memory alloys were found similar to the strength of bones. In the present research, NiTi SMA is fabricated by powder metallurgy process. The processing parameters of sintering and compaction (i.e. compaction pressure, sintering temperature and sintering time) play an important role in the porosity investigation of SMA. Taguchi’s method based $$\hbox {L}_{9}$$ orthogonal array was selected for the planning of experiments. Sintering temperature and sintering time were the significant process parameters as compared to compaction pressure. Regression coefficients and equation was derived by use of regression analysis. Further this equation was solved with the help of genetic programming and results of both (i.e. Taguchi’ method and genetic programming) were compared to find the maximum porosity. The maximum porosity that can be achieved is 56 % and the confirmation experiments were performed at 95 % confidence level.

Abstract: The use of finite element analyses in the design of geotechnical problems is mainly related to the choice of mechanical characteristics (parameters) of soil. Therefore, the optimization of these parameters is considered as the most important step in geotechnics. The main objective of this work is to identify the mechanical parameters based on Mohr–Coulomb model, by conducting pressuremeter tests on synthetic clayey soil, using Taguchi’s experimental design method. The Taguchi L16 orthogonal array is widely adopted as a modeling support for the simulation of the pressuremeter test, using the finite element software Plaxis. Then, a statistical treatment of the obtained results is carried out based on the concept of the analysis of variance and the development of a mathematical model based on the response surface methodology, in order to identify the significant factors of the model and their interactions. Finally, the optimal values of factors might be chosen using result analysis of Taguchi’s experimental design method, combined with the desirability function approach. This study has shown that the proposed approach is an efficient and effective tool for the identification of soil parameters.

Abstract: In the present study, two mathematical models were developed to optimize the surface roughness for machining condition of Cedar of Lebanon pine (Cedrus libani). Taguchi approach was applied to examine the effect of CNC processing variables. Quality characteristics parameters were selected as arithmetic average roughness (Ra) and average maximum height of the profile (Rz) for wood material. Analysis of variance (ANOVA) was used to determine effective machining parameters. Developed mathematical models using response surface methodology (RSM) were optimized by a combined approach of the Taguchi’s L27 orthogonal array based simulated angling algorithm (SA). Optimum machining levels for determining the minimum surface roughness values were carried out three stages. Firstly, the desirability function wasused to optimize the mathematical models. Secondly, the results obtained from the desirability function were selected as the initial point for the simulated angling algorithm. Finally, the optimum parameter values were obtained by using simulated angling algorithm. Minimum Ra value was obtained spindle speed of 17377 rpm, feed rate of 2.012 m/min, tool radius of 8 mm and depth of cut of 2.009 mm by using desirability function based simulated angling algorithm. For Rz these results were found as 16980 rpm, 2.004 m/min, 8.001mm and 2.003 mm. The R-square values of the Ra and Rz were 95.91 % and 96.12 %, respectively. The proposed models obtained the minimum surface roughness values and provided better results than the observed values.

Abstract: Because of measurement errors and unknown influential input process parameters, unavoidable scatter can be expected in the nonlinear output response of repeated experiments. The Taguchi method suggests an orthogonal array for identifying optimum input process parameters by performing a few tests and confirming through experiments (if necessary). This article provides a simple methodology and its validation by tracing the optimum gas metal arc welding (GMAW) process parameters on the %weld dilution of ST-37 steel plates. It is possible to specify the expected range of the weld dilution for the GMAW process parameters.

Abstract: Metal matrix composites have become a vital concern for the modern manufacturing companies due to some of their special properties. The presence of reinforcement makes them difficult in machining operations to achieve industrial requirements. Therefore, it is necessary to optimize the machining process parameters to improve output performance in terms of product quality. The overall performance of the wire electrical discharge machining (WEDM) process is influenced by various parameters, such as pulse-on time, pulse-off time, induced current, and wire-feed. WEDM is one of the non-traditional machining processes. It machines only electrically conducting materials and machines the surfaces by the thermo-electrical process. During machining of composites, material removal rate, cutting speed, and surface roughness have been considered for this research. The relation between the process parameters and the output responses is developed by using linear regression analysis through Minitab-17. The experiments conducted are dependent on Taguchi $${\hbox {L}}_{25}$$ orthogonal array. The optimized sets of process parameters are obtained by using teaching and learning-based optimization.

Abstract: This work introduces the determination of the optimum values of the design parameters in a tube with loose-fit perforated twisted tapes. The effects of the design parameters such as twist ratio (y/D), width ratio (W/D), hole diameter ratio (d/D) and Reynolds number (Re) on heat transfer (i.e. Nusselt number) and pressure drop (i.e. friction factor) were analyzed by Taguchi method (TM) and grey relational analysis (GRA). The Nusselt number and friction factor were taken into account as performance parameters. Taguchi Method is based on analysis of variances and implements the orthogonal arrays for experimental design. L16 orthogonal array was selected as experimental plan. Firstly, each performance parameter was optimized, independently. Then, all the performance parameters were optimized together by TM and GRA. According to the experimental plan results, the most important factor for both Nusselt number and friction factor is Reynolds number, while the least significant factors are twist ratio (y/D) and width ratio (W/D).

Abstract: As surveyed, many efforts have been made to model the performances of electrical discharge machining (EDM) using artificial neural network (ANN). However, the selections of the network parameters were mostly prepared in a random manner, resulting to unnecessary trials. Thus, orthogonal array (Taguchi) is employed in the procedure of network function and network architecture assortment to avoid excessive random trial experimentations. This proposed orthogonal based ANN modelling is employed on WEDM of Ti–48Al intermetallic alloys. Meanwhile modified multi objective genetic algorithm (multiGA) is used as the optimization technique. Material removal rate (MRR), surface roughness (Ra), cutting speed (Vc) and width of kerf (Dk) are the machining performances considered in this study. Five machining parameters observed from the previous researches are chosen as significant factors to the machining performances in this study, which are pulse on time, pulse off time, peak current, feed rate and servo voltage. Experimental studies are carried out to verify the machining performances suggested by this approach. Feed forward back propagation neural network (FFNN) is found to be the best network type on the selected dataset. Two hidden layer 5–6–6–4 FFNN showed the most precise and generalized network architecture with very good prediction accuracy. The proposed approach, OrthoANN, reduced ANN experimentation time by a large scale and produced viable results for machining optimization when integrated with multiGA.

Abstract: This paper employs Taguchi-fuzzy approach for parametric optimisation of electric discharge machining with multiple performance measures. In this work, seven input parameters (one of two levels and six of three levels) and two performance measures have been considered and the experiments are designed using Taguchi’s L36 orthogonal array. A fuzzy model is formed using mamdani inference system and optimal combination of process parameters has been obtained on basis of multi-performance fuzzy index (MPFI) value calculated using different shapes of membership functions (MF) viz. triangular, trapezoidal and gaussian. Gaussian MF is found to provide better results as compared to triangular and trapezoidal MF. ANOVA analysis has also been carried out on MPFI to find out percentage contribution. It is shown with the help of confirmatory experiments that MRR and SR are improved by 103.25 and 32.11% respectively by employing the proposed approach.

Abstract: This study presents the optimization of machining parameters on ZE41 Mg alloy fabricated by gravity die casting and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). Focus on the optimization of machining parameters using the technique to get minimum surface roughness, cutting force, thermal stress, residual stress, chip thickness and maximum MRR. A number of machining experiments were conducted based on the L27 orthogonal array on computer numerical control vertical machining center. The experiments were performed on ZE41 using cutting tool of an ISO 460. 1-1140-034A0-XM GC3 of 20, 25 and 30mm diameter with cutting point 140 degrees, for different cutting conditions. TOPSIS and ANOVA were used to work out the fore most important parameters cutting speed, feed rate, depth of cut and tool diameter which affect the response. The expected values and measured values are fairly close. Finally, the study for optimizing machining process is surveyed and results show improvement in real experiments.