Process parameters optimization for friction stir welding of RDE-40 aluminium alloy using Taguchi technique

Taguchi approach was applied to determine the most influential control factors which will yield better tensile strength of the joints of friction stir welded RDE-40 aluminium alloy. In order to evaluate the effect of process parameters such as tool rotational speed, traverse speed and axial force on tensile strength of friction stir welded RDE-40 aluminium alloy, Taguchi parametric design and optimization approach was used. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined. The results indicate that the rotational speed, welding speed and axial force are the significant parameters in deciding the tensile strength of the joint. The predicted optimal value of tensile strength of friction stir welded RDE-40 aluminium alloy is 303 MPa. The results were confirmed by further experiments.     

Optimization of Tribological Properties in Aluminum Hybrid Metal Matrix Composites Using Gray-Taguchi Method

This article investigates the optimization of dry sliding performances on the aluminum hybrid metal matrix composites using gray relational analysis in the Taguchi method. Different loads, sliding speeds and varying percentage of molybdenum disulfide are selected as control factors. The multiple responses to evaluate the dry sliding performances are specific wear rate and coefficient of friction. Using a pin-on-disk apparatus, the volume loss and frictional force are measured. Based on gray relational analysis, the optimum level parameters for specific wear rate and coefficient of friction have been identified. An L27 orthogonal array was employed for the experimental design. Analysis of Variance (ANOVA) had given the impact of individual factors and interactions on the specific wear rate as well as the coefficient of friction. The results indicated that the three test parameters had a significant role in controlling the friction and wear behavior of composites. Interaction of the control factors showed the sizable influence on tribological performance. Using Scanning Electron Microscopy (SEM) the wear surface morphology and wear mechanism of the composites have been investigated.     

Optimization of a Three-Component Green Corrosion Inhibitor Mixture for Using in Cooling Water by Experimental Design

Factors such as inhibitor concentration, solution hydrodynamics, and temperature influence the performance of corrosion inhibitor mixtures. The simultaneous studying of the impact of different factors is a time- and cost-consuming process. The use of experimental design methods can be useful in minimizing the number of experiments and finding local optimized conditions for factors under the investigation. In the present work, the inhibition performance of a three-component inhibitor mixture against corrosion of St37 steel rotating disk electrode, RDE, was studied. The mixture was composed of citric acid, lanthanum(III) nitrate, and tetrabutylammonium perchlorate. In order to decrease the number of experiments, the L16 Taguchi orthogonal array was used. The “control factors” were the concentration of each component and the rotation rate of RDE and the “response factor” was the inhibition efficiency. The scanning electron microscopy and energy dispersive x-ray spectroscopy techniques verified the formation of islands of adsorbed citrate complexes with lanthanum ions and insoluble lanthanum(III) hydroxide. From the Taguchi analysis results the mixture of 0.50 mM lanthanum(III) nitrate, 0.50 mM citric acid, and 2.0 mM tetrabutylammonium perchlorate under the electrode rotation rate of 1000 rpm was found as optimum conditions.     

AZ80镁合金挤压铸造工艺参数的形态学矩阵优化(英文)

运用形态学矩阵对AZ80镁合金挤压铸造工艺参数进行优化。采用 L9(33)田口方法中的正交列对不同挤压压力、模具预热温度和压力持续时间进行组合。采用一个3水平正交阵列确定信噪比,通过方差分析确定影响力学性能最重要的工艺参数,并利用多变量线性回归分析确定拉伸强度、伸长率和硬度,获得了最佳的挤压铸造工艺参数。     

搅拌摩擦技术制备AA6061/SiC纳米复合材料的工艺参数优化(英文)

采用搅拌摩擦技术制备AA6061/SiC纳米复合材料,并用实验设计方法来确定影响AA6061/SiC复合材料极限拉伸强度的重要因素,包括4种因素,即旋转速度、横向速度、切削深度、搅拌头形状。运用Taguchi方法,得到优化的工艺参数。方差分析表明,旋转速度是最主要的影响因素。统计分析结果表明,采用带螺纹的搅拌头得到的复合材料的极限拉伸强度比采用方型搅拌头的高。搅拌头的旋转速度越快、横向速度越慢,则复合材料的极限拉伸强度越高。     

注射工艺参数对薄壳塑件翘曲变形的影响

在分析翘曲变形理论的基础上,利用Taguchi实验方法设计了L9实验矩阵对塑件注射成型过程进行模拟研究,并采用标准变量分析方法,分析了模具温度、熔体温度、注射速率、保压压力等工艺因素对塑件翘曲变形的影响。研究表明:所选择的工艺因数对塑件不同方向上的翘曲变形有着不同程度的影响,优化的工艺组合可以使塑件翘曲变形达到最小,从而提高塑件质量。     

Time-modulated CVD process optimized using the taguchi method

The Taguchi method is used herein to optimize the time-modulated chemical vapor deposition (TMCVD) process. TMCVD can be used to deposit smooth, nanocrystalline diamond (NCD) coatings onto a range of substrate materials. The implementation of the Taguchi method to optimize the TMCVD process can save time, effort, and money. The Taguchi method significantly reduces the number of experiments required to optimize a fabrication process. In this study, the effect of five TMCVD process parameters is investigated with respect to five key factors of the as-grown samples. Each parameter was varied at four different values (experimental levels). The five key factors, taking into consideration the experimental levels, were optimized after performing only 16 experiments. The as-grown films were characterized for hardness, quality, surface roughness, and microstructure using scanning electron microscopy, Raman spectroscopy, surface profilometry, and Vickers hardness testing. This paper was presented at the fourth International Surface Engineering Congress and Exposition held August 1–3, 2005 in St. Paul, MN.     

应用Taguchi实验设计法最小化ABS注塑制品翘曲变形量

运用Taguchi DOE技术研究了工艺参数对丙烯腈-丁二烯-苯乙烯共聚物(ABS)注塑制品翘曲变形的影响,并获得优化的工艺参数以使制品的翘曲变形量最小。文中以碱性蓄电池盖为例,利用L9(34)正交矩阵进行实验,并采用标准变量分析法(ANOVA)对熔体温度、注射时间、冷却时间、保压压力等工艺参数对制品翘曲变形的影响程度进行了研究,结果表明,在所选工艺参数中,保压压力和熔体温度对翘曲变形的影响程度最大。     

Optimization of Friction Welding of Tube-to-Tube Plate Using an External Tool with Filler Plate

Friction welding of tube-to-tube plate using an external tool (FWTPET) process with filler plate was successfully applied and optimized for joining commercially pure aluminum tube and tube plate. Taguchi approach was applied to determine the most influential control factors which will yield better joint strength. L₉ orthogonal array was used in this study. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined. The percentage of contribution of each process parameter was determined by Analysis of variance. The predicted optimal value of joint strength was found to be 83.26?MPa. The results were confirmed by further experiments.     

基于Taguchi的轮毂套管热挤压工艺优化

热挤压工艺参数对汽车轮毂套管的锻造性能和服役寿命具有重要的影响.首次采用Taguchi理论对EQ153汽车轮毂套管的热挤压工艺进行最优化处理.以不同工艺下的损伤、应变和应力作为目标值,通过灰关联分析和方差分析得到初锻温度、挤压速度和摩擦系数的最佳水平.优化结果良好,对轮毂套管的热挤压具有指导意义.     

滑动轴承冲压成形的有限元数值模拟

以滑动轴承的冲压成形为研究对象,利用ANSYS／LS-DYNA软件显式算法,实现滑动轴承扩口翻边的整个模拟过程。影响滑动轴承冲压成形的主要因素有凸模锥角、摩擦系数和冲压力。通过对这些因素进行Taguchi正交实验设计,分析各因素对冲压过程中应力应变的不同程度的影响。研究表明,合适的凸模锥角和压力对滑动轴承冲压成形具有很大的影响作用。研究结果对滑动轴承的成形工艺制定和模具结构设计具有一定的指导作用。     

Multiperformance Optimization in Turning of Free-Machining Steel Using Taguchi Method and Utility Concept

This article presents the application of Taguchi method and the utility concept for optimizing the machining parameters in turning of free-machining steel using a cemented carbide tool. A set of optimal process parameters, such as feed rate, cutting speed, and depth of cut on two multiple performance characteristics, namely, surface roughness and metal removal rate (MRR) is developed. The experiments were planned as per L ₉ orthogonal array. The optimal level of the process parameters was determined through the analysis of means (ANOM). The relative importance among the process parameters was identified through the analysis of variance (ANOVA). The ANOVA results indicated that the most significant process parameter is cutting speed followed by depth of cut that affect the optimization of multiple performance characteristics. The confirmation tests with optimal levels of machining parameters were carried out to illustrate the effectiveness of Taguchi optimization method. The optimization results revealed that a combination of higher levels of cutting speed and depth of cut along with feed rate in the medium level is essential in order to simultaneously minimize the surface roughness and to maximize the MRR.     

Optimization of the coating parameters for micro-arc oxidation of Cp-Ti

TiO₂ coatings were formed on the surface of CP-Ti by AC pulse micro-arc oxidation. The structural, mechanical, corrosion and tribological properties were analyzed by using XRD, SEM, microhardness tester, surface profilometer, electrochemical polarization unit and pin-on-disk tribotester. Potential, solution, frequency and duration time were chosen as the coating parameters and three levels for each parameter were determined. By determining the corrosion current density, corrosion potential, wear rate, friction coefficient and surface hardness, the optimum working conditions were determined by using a Taguchi design of experiment. After micro-arc oxidation, the aim is to minimize current density, the friction coefficient and the wear rate and to maximize corrosion potential and surface hardness after micro-arc oxidation. While the optimum conditions were determined, due to existence of more than one goal, a trade-off among goals was considered. First of all, each goal was optimized separately, and then all the goals were optimized together, considering the priority of the goals.     

Taguchi Optimization on the Initial Thickness and Pre-aging of Nano-/Ultrafine-Grained Al-0.2 wt.%Sc Alloy Produced by ARB

In this study, Taguchi design method with L₉ orthogonal array has been used to optimize the initial thickness and pre-aging parameters (temperature and time) for the mechanical properties of Al-0.2 wt.% Sc alloy heavily deformed by accumulative roll bonding (ARB) up to ten cycles. Analysis of variance was performed on the measured data and signal-to-noise ratios. It was found that the pre-aging temperature has the most significant parameter affecting the mechanical properties by percentage contribution of 64.51%. Pre-aging time (19.29%) has the next most significant effect, while initial thickness (5.31%) has statistically less significant effect. In order to confirm experimental conclusions, verification experiments were carried out at optimum working conditions. Under these conditions, the yield strength was 6.51 times higher and toughness was 6.86% lower compared with the starting Al-Sc material. Moreover, mean grain size was decreased to 220 nm by setting the control parameters, which was the lowest value obtained in this study. It was concluded that the Taguchi method was found to be a promising technique to obtain the optimum conditions for such studies. Consequently, by controlling the parameter levels, the high-strength and high-toughness Al-Sc samples were fabricated through pre-aging and subsequent ARB process.     

Experimental Investigation on Friction Welding of UNS S32205 Duplex Stainless Steel

UNS S 32205 duplex stainless steel specimens were joined by continuous drive friction welding process. The experiments were conducted as per the Taguchi（L16 orthogonal array） method. The friction welding process parameters such as heating pressure, heating time, upsetting pressure, upsetting time, and speed of rotation were fixed with low,medium, and high levels of range based on the machine capacity, and the required knowledge was acquired from the preliminary experiments. The joint characterization studies included micro structural examination and evaluation of mechanical properties of the joints. Microhardness variation, impact toughness, and tensile strength of the joints were evaluated. Neither a crack nor an incomplete bonding zone was observed. The tensile strength of the joints was higher than the strength of the base material, and the friction and upsetting pressures were found to influence the joint strength. The tensile strength of all the welds was observed to be increasing with an increase in the rotational speed. The toughness of the friction welds was evaluated at room temperature and also at subzero（cryo） temperature conditions. The toughness for friction welds was found to be superior to the fusion welds of duplex stainless steel at room temperature and cryo conditions. Weldments exhibited better corrosion resistance than the parent material.     

Optimization of Binder Jetting Using Taguchi Method

Among several additive manufacturing (AM) methods, binder-jetting has undergone a recent advancement in its ability to process metal powders through selective deposition of binders on a powder bed followed by curing, sintering, and infiltration. This study analyzes the impact of various process parameters in binder jetting on mechanical properties of sintered AM metal parts. The Taguchi optimization method has been employed to determine the optimum AM parameters to improve transverse rupture strength (TRS), specifically: binder saturation, layer thickness, roll speed, and feed-to-powder ratio. The effects of the selected process parameters on the TRS performance of sintered SS 316L samples are studied with the American Society of Testing Materials (ASTM) standard test method. It was found that binder saturation and feed-to-powder ratio were the most critical parameters, which reflects the strong influence of binder powder interaction and density of powder bed on resulting mechanical properties. This article serves as an aid in understanding the optimum process parameters for binder jetting of SS 316L.     

冲压成形仿真数据的主成分与模糊聚类分析

冲压成形数值仿真结果中隐含着大量的领域知识。文章将主成分分析与模糊聚类方法应用于基于仿真模型与模拟结果数据的冲压件相似性判别与成形性能判别。通过对油箱冲压成形有限元仿真结果数据进行处理,分析了压边力、拉延筋设置参数、摩擦系数等工艺参数对成形性能的相对重要程度;构造了油箱成形性能的模糊概念,描述其破裂、起皱程度。通过对汽车覆盖件有限元模型数据的分析,对汽车覆盖件进行模糊分类及相似性判别。结果表明,面向有限元仿真结果的数据挖掘技术,可以为冲压成形领域知识发现提供一种有效的新途径。     

田口设计优化的铝合金旋转叶轮除气技术

利用田口实验优化法配合水模拟实验法设计了铝合金旋转叶轮除气技术.选用L9田口正交表分析旋转叶轮除气技术的3个控制因子,包括转速、气体流量及叶轮设计.研究结果显示,使用水模拟实验法配合田口实验法,可有效的减少设计优化旋转叶轮除气技术的实验数.通过田口实验法,得出旋转叶轮除气技术的最佳参数组合,其中最重要的控制因子为转头的叶轮数目、转速和气体流量,最佳参数分别为6个叶轮片、转速500 rpm及除气气体流量2L/min.     

Optimisation of Nd–YAG laser welding of superduplex stainless steel by parameter design

Abstract

Many researchers have found the welding of super duplex stainless steel UNS S32760 (Zeron 100) by high power CO₂ laser to be an unacceptable process, because the austenite/ferrite (γ/α) ratio in the laser weld bead normally deviates significantly from the optimum balance of 50 : 50. To date, the best γ/αratio in a laser weld reported in the published literature was ～30 : 70. The high percentage of ferrite would result in lower strength and poor corrosion properties. The present investigation was aimed at achieving a near 50 : 50 γ/αratio laser weld using the Nd–YAG laser. These lasers have more process parameters that can be varied, compared to CO₂ lasers. Three different kinds of output power waveform, continuous, sine, and square waves, together with many other parameters, were investigated. The Taguchi method was used for parameter design, to reduce the number of experiments. Based on the Taguchi approach, optimum process parameters were determined and laser weld beads that consisted of 55 : 45 γ/α were achieved.     

模糊田口法在重切削制程中切削参数最佳化设计

为了快速有效获得重切削时良好的切削性能参数,以田口法与模糊逻辑相结合,对侧面铣削SUS304不锈钢重切削制程时的切削参数进行最佳化设计。由于评估重切削制程的刀具寿命与金属移除率两项主要切削性能,受到主轴转速、每刃进给、轴向切深与径向切深的影响,由此将4个切削参数设置为可控制因子。经过田口法将各品质特性转化为S/N比,通过模糊逻辑运算,采用多重品质特性指标(MPCI)求得切削参数最佳水准组合。试验结果表明:以模糊田口法获得的切削参数最佳水准组合,能够有效改善侧面重切削制程时的切削性能,为刀具制造厂或刀具使用者寻求最佳切削条件提供参考。