Optimization of PVD process parameter for coating AZ91D magnesium alloy by Taguchi grey approach

This study was an attempt made to explore the possibility of increasing the surface properties of the AZ91D magnesium alloy by applying ZrO_(2)coating using Physical Vapour Deposition(PVD-RF)sputtering process.In order to improve the quality of the coating,the PVD process parameter with multiple performance characteristics was optimized by using the Taguchi grey approach.L 18 orthogonal array was selected for conducting the experiments.The proposed Taguchi grey method was find out the optimal process parameter for multiple performance characteristics.The optimal combination was attained at chamber pressure of 0.003 bar,argon gas in millibar and power input of 200 W.The validation experiment result shows an improvement in the micro hardness and surface finish.Also,the performance characterizations such as SEM,EDX,XRD,coating thickness,surface roughness and micro hardness were measured at optimal process parameter.

Optimization of green sand mould system using Taguchi based grey relational analysis

The strength of the mould cavity in sand casting is very much significant to attain high-quality castings. Optimization of green sand process parameters plays a vital role in minimizing casting defects. In the present research work, the effect of process parameters such as AFS grain fineness number, water, molasses, bentonite, fly ash, and ramming, and their levels on the resultant mould properties were investigated and optimized using Taguchi based grey relational analysis. The Taguchi L18 orthogonal array and analysis of variance(ANOVA) were used. The quality characteristics viz., green compression strength, permeability, bulk density, mould hardness and shatter index of green sand mould were optimized using grey relational grade, based on the experiments designed using Taguchi's Design of Experiments. ANOVA analysis indicated that water content is the most influential parameter followed by bentonite, and degree of ramming that contributes to the quality characteristics. The results are confirmed by calculating confidence intervals, which lies within the interval limits. Finally, microstructure observations and X-ray diffraction analysis have been performed for the optimal sand parametric combination. Results show that presence of maximum amount of SiO_2, which might be the reason for enhancement of the physical properties of the sand.

Optimization of cutting parameters with Taguchi and grey relational analysis methods in MQL-assisted face milling of AISI O2 steel

This study aims to examine the usability of environmentally harmless vegetable oil in the minimum quantity of lubrication(MQL)system in face milling of AISI O2 steel and to optimize the cutting parameters by different statistical methods.Vegetable oil was preferred as cutting fluid,and Taguchi method was used in the preparation of the test pattern.After testing with the prepared test pattern,cutting performance in all parameters has been improved according to dry conditions thanks to the MQL system.The highest tool life was obtained by using cutting parameters of 7.5 m cutting length,100 m/min cutting speed,100 mL/h MQL flow rate and 0.1 mm/tooth feed rate.Optimum cutting parameters were determined according to the Taguchi analysis,and the obtained parameters were confirmed with the verification tests.In addition,the optimum test parameter was determined by applying the gray relational analysis method.After using ANOVA analysis according to the measured surface roughness and cutting force values,the most effective cutting parameter was observed to be the feed rate.In addition,the models for surface roughness and cutting force values were obtained with precisions of 99.63%and 99.68%,respectively.Effective wear mechanisms were found to be abrasion and adhesion.

Multi-response optimization of process parameters in friction stir welded AM20 magnesium alloy by Taguchi grey relational analysis

The purpose of this paper is to optimize the process parameter to get the better mechanical properties of friction stir welded AM20 magnesium alloy using Taguchi Grey relational analysis(GRA).The considered process parameters are welding speed,tool rotation speed,shoulder diameter and plunging depth.The experiments were carried out by using Taguchi's L18 factorial design of experiment.The processes parameters were optimized and ranked the parameters based on the GRA.The percentage influence of each process parameter on the weld quality was also quantified.A validation experimental run was conducted using optimal process condition,which was obtained from the analysis,to show the improvement in mechanical properties of the joint.This study also shows the feasibility of the GRA with Taguchi technique for improvement in welding quality of magnesium alloy.

Optimisation of laser welding parameters for welding of P92 material using Taguchi based grey relational analysis

Creep strength enhanced ferritic(CSEF) steels are used in advanced power plant systems for high temperature applications. P92(Cr–W–Mo–V)steel, classified under CSEF steels, is a candidate material for piping, tubing, etc., in ultra-super critical and advanced ultra-super critical boiler applications. In the present work, laser welding process has been optimised for P92 material by using Taguchi based grey relational analysis(GRA).Bead on plate(BOP) trials were carried out using a 3.5 k W diffusion cooled slab CO_2 laser by varying laser power, welding speed and focal position. The optimum parameters have been derived by considering the responses such as depth of penetration, weld width and heat affected zone(HAZ) width. Analysis of variance(ANOVA) has been used to analyse the effect of different parameters on the responses. Based on ANOVA, laser power of 3 k W, welding speed of 1 m/min and focal plane at-4 mm have evolved as optimised set of parameters. The responses of the optimised parameters obtained using the GRA have been verified experimentally and found to closely correlate with the predicted value.? 2016 China Ordnance Society. Production and hosting by Elsevier B.V. All rights reserved.

Optimization of back bead geometry in the PMAG-TIG twin arc hybrid root welding process using grey based Taguchi method

This study investigated multi-response optimization of the pulse metal active gas-tungsten inert gas( PMAG-TIG) twin arc hybrid root welding process for an optimal parametric combination to yield favorable back bead geometry of welded joints using grey relational analysis and Taguchi method.Eighteen experimental runs based on an orthogonal array following the Taguchi method were performed to derive objective functions to be optimized within the experimental domain.The objective functions were selected in relation to parameters of PMAG-TIG twin arc root welding back bead geometry: back bead width to root reinforcement ratio and deposited metal height.The Taguchi approach was followed by grey relational analysis to solve the multi-response optimization problem.The significance of factors on overall quality characteristics of the weld joint was also evaluated quantitatively using analysis of variance.Optimal results were verified through additional experiments,and showed to feasibility of applying grey relation analysis in combination with Taguchi technique for continuous improvement of product quality in the manufacturing industry.

Multi objective prediction and optimization of control parameters in the milling of aluminium hybrid metal matrix composites using ANN and Taguchi-grey relational analysis

This study aims to optimize the input parameters such as mass fraction and particle size of SiC along with depth of cut,feed and cutting speed in the milling of Al5059/SiC/MoS2.The hybrid metal matrix composites are generally fabricated by reinforcing of different sizes(10,20,40 μm)of SiC with aluminium at a different levels(5%,10%& 15%)whereas the MoS2 addition is fixed as 2%.The effect of each control factor on response variables are analyzed through Taguchi S/N ratio method.Also,the most significant method for prediction of response parameters is satisfied by ANN model than the regression model.Analysis of variance(ANOVA)results envisage that mass fraction of SiC,feed rate is the most domineering factor on response variable.

Optimizing SUS 304 wire drawing process by grey relational analysis utilizing Taguchi method

In the stainless steel 304 （SUS 304） wire drawing process, optimizing the die life and wire tensile strength, which are the larger-the-better quality characteristics （QCH） types, is of main interest. Three control factors, involving reduction ratio, lubricant temperature, and drawing speed, were investigated utilizing L9（34） orthogonal array （OA）. The grey relational analysis was conducted for the normalized signal-to-noise （S/N） ratios. The ordinal value of the grey grade was then used to decide optimal factor levels. The anticipated improvements in die life and wire tensile strength were estimated 25.31 h and 22.50 kg/mm2, respectively. To decide the significant factor which had effect on each QCH and predict the average value of each QCH, analysis of variance （ANOVA） was performed for S/N ratio and QCH. Confirmation experiments were then conducted, where a good overlap was noticed between the predicted and confirnation intervals for each QCH. The Hotelling T2 and the sample generalized variance control charts were finally utilized in controlling and monitoring future production. In conclusion, the grey relational analysis utilizing Taguchi method is an effective approach for optimizing the die life and wire tensile strength for SUS wire drawing process. 2008 University of Science and Technology Beijing. All rights reserved.

Multi-Objective Optimization of Fused Deposition Modeling for Mechanical Properties of Biopolymer Parts Using the Grey-Taguchi Method

The urgent need to develop customized functional products only possible by 3D printing had realized when faced with the unavailability of medical devices like surgical instruments during the coronavirus-19 disease and the ondemand necessity to perform surgery during space missions.Biopolymers have recently been the most appropriate option for fabricating surgical instruments via 3D printing in terms of cheaper and faster processing.Among all 3D printing techniques,fused deposition modelling(FDM)is a low-cost and more rapid printing technique.This article proposes the fabrication of surgical instruments,namely,forceps and hemostat using the fused deposition modeling(FDM)process.Excellent mechanical properties are the only indicator to judge the quality of the functional parts.The mechanical properties of FDM-processed parts depend on various process parameters.These parameters are layer height,infill pattern,top/bottom pattern,number of top/bottom layers,infill density,flow,number of shells,printing temperature,build plate temperature,printing speed,and fan speed.Tensile strength and modulus of elasticity are chosen as evaluation indexes to ascertain the mechanical properties of polylactic acid(PLA)parts printed by FDM.The experiments have performed through Taguchi’s L27orthogonal array(OA).Variance analysis(ANOVA)ascertains the significance of the process parameters and their percent contributions to the evaluation indexes.Finally,as a multiobjective optimization technique,grey relational analysis(GRA)obtains an optimal set of FDM process parameters to fabricate the best parts with comprehensive mechanical properties.Scanning electron microscopy(SEM)examines the types of defects and strong bonding between rasters.The proposed research ensures the successful fabrication of functional surgical tools with substantial ultimate tensile strength(42.6 MPa)and modulus of elasticity(3274 MPa).

Study of Potentiodynamic Polarization Behaviour of Electroless Ni-B Coatings and Optimization using Taguchi Method and Grey Relational Analysis

Electroless nickel coatings are very popular for their corrosion resistant actions. The present article attempts to study the corrosion behaviour of electroless Ni-B coatings by varying the coating parameters viz. bath temperature, reducing agent concentration and nickel source concentration together with the annealing temperature. The electrochemical parameters viz., corrosion potential and corrosion current density are evaluated with the help of potentiodynamic polarization experimentation. Taguchi based Grey analysis is employed in order to optimize this multiple response problem and the optimal combination of parameters for maximum corrosion resistance for Ni-B coatings is presented. Moreover, analysis of variance reveals that bath temperature and concentration of nickel source have significant influence on the corrosion performance of the coating. The microstructure characterization of the coating is also conducted with the help of scanning electron microscopy, energy dispersive X-ray analysis and X-ray diffraction analysis. The Ni-B coating in general exhibits a nodular structure and turns crystalline with heat treatment. The corroded surface exhibits cracks and black spots which imply the occurrence of localized corrosion.

Optimization of Tribological Performance of Al-6061T6-15% SiCp-15% Al₂O₃Hybrid Metal Matrix Composites Using Taguchi Method &Grey Relational Analysis

In this investigation, optimization of tribological performance parameters of Al-6061T6 alloy reinforced with SiC (15% by weight) and Al2O3 (15% by weight) particulates having particle size of 37 μm each has been presented. The wear and frictional properties of the hybrid metal matrix composites have been studied by performing dry sliding wear test using pin-on-disc wear tester. A L27 orthogonal array is selected for the analysis of the data. From the test results it is observed that sliding distance has the significant contribution in controlling the friction and wear behaviour of hybrid composites. A confirmation test is also carried out to verify the accuracy of the results obtained through the optimization. In addition an optical micrograph test is also performed on the wear tracks to study the wear mechanism.

Optimizing the Glass Fiber Cutting Process Using the Taguchi Methods and Grey Relational Analysis

This paper mainly describes a new approach to optimizing of the cutting glass fiber with multiple performance characteristics, based on reliability analysis, Taguchi and Grey methods. During the cutting process, the speed, the volume and the cutting load are optimized cutting parameters when the performance characteristics, which include Weibull modulus and blade wear, are taken into consideration. In this paper, optimization with multiple performance characteristics is found to be the highest cutting speed and the smallest cutting volume, and the medium cutting load. An analysis of the variance of the blade wear indicates that the cutting speed (47.21%), the cutting volume (14.62%) and the cutting load (12.20%) are the most significant parameters in the cutting process of glass fibers. In summary, the most optimal cutting parameter should be A3B1C2. The results of experiments have shown that the multiple performance characteristics of cutting glass fiber are improved effectively through this approach.

A Hybrid Optimization Approach of Single Point Incremental Sheet Forming of AISI 316L Stainless Steel Using Grey Relation Analysis Coupled with Principal Component Analysiss

We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were used to develop double wall angle pyramid with aid of tungsten carbide tool. GRA coupled with PCA was used to plan the experiment conditions. Control factors such as Tool Diameter(TD), Step Depth(SD), Bottom Wall Angle(BWA), Feed Rate(FR) and Spindle Speed(SS) on Top Wall Angle(TWA) and Top Wall Angle Surface Roughness(TWASR) have been studied. Wall angle increases with increasing tool diameter due to large contact area between tool and workpiece. As the step depth, feed rate and spindle speed increase,TWASR decreases with increasing tool diameter. As the step depth increasing, the hydrostatic stress is raised causing severe cracks in the deformed surface. Hence it was concluded that the proposed hybrid method was suitable for optimizing the factors and response.

Optimization of tribological parameters over WC-12%Co laser alloyedpearlitic ductile iron using Taguchi based Grey relational analysis

Pearlitic ductile irons(PDIs)are used in transportation and nuclear energy industries.In heavy loading situation,the service life of PDI is affected by numerous tribo aspects.In this study,surface of the PDI is alloyed with WC-12%Co powder using a high power fibre laser.The wear properties of the base material and laser alloying samples were investigated by tribometer with various parameters,i.e.,temperature,load and sliding speed.Based on experimental test,the load has maximum percentage of contribution and followed by sliding speed and working temperature.The optimized tribological parameters by Grey relational analysis(GRA)were established and those values are closely matched with predicted values.Besides,base material and laser alloying surfaces were examined through Vickers hardness machine,scanning electron microscopy(SEM)and roughness tester.The laser altered specimen shows no defects and improves the wear properties than substrates.The identified optimal tribological parameters are load of 30 N,speed of 0.5 m/s and working temperature of 300℃,and load of 30 N,speed of 0.5 m/s and working temperature of 200℃ for base metal and laser alloying samples,respectively.

Multiple Response Optimization of Three-Body Abrasive Wear Behaviour of Graphite Filled Carbon-Epoxy ComPosites Using Grey-Based Taguchi Approach

The three-body abrasive wear behaviour of carbon fabric reinforced epoxy (C-E) composites has been evaluated by the addition of graphite (G) particles as a secondary reinforcement. Three-body abrasive wear test were conducted using dry sand rubber wheel abrasion tester as per ASTM G-65 with three process parameters load, abrading distance and filler content. To assess the abrasive wear behaviour of particulate filled C-E composites satisfying multiple performance measure, grey-based Taguchi approach has been adopted. The experiments were designed according to Taguchi’s orthogonal array (L?27). The grey relational analysis was applied to convert a multi response process optimization to a single response. Using analysis of variance, significant contributions of process parameters have been determined. The results indicate that the addition of graphite particles into C-E composite increased the wear resistance considerably. It was observed that highest wear resistance of C-E composite was achieved with incorporation of 10 wt. % of graphite filler. Results indicate that the filler content and grit size of abrasive paper were found to be the most significant factor which has influence on the abrasive wear of C-E composite. The worn surface features were examined through scanning electron microscope to probe the wear mechanism.

Wear Behaviour of Al-SiCp Metal Matrix Composites and Optimization Using Taguchi Method and Grey Relational Analysis

Aluminium metal matrix composite is a relatively new material that has proved its position in automobile, aerospace and other engineering design applications due to its wear resistance and substantial hardness. Need for improved tribological performance has led to the design and selection of newer variants of the composite. The present investigation deals with the study of wear behaviour of Al-SiCp metal matrix composite for varying reinforcement content, applied load, sliding speed and time. Aluminium metal matrix composites reinforced with SiC particles are prepared by liquid metallurgy route using LM6 aluminium alloy and silicon carbide particles (size ~ 37 μm) by varying the weight fraction of SiC in the range of 5% - 10%. The material is synthesized by stir casting process in an electric melting furnace. The materials are then subjected to wear testing in a multitribotester using block on roller configuration. A plan of experiments based on L27 Taguchi orthogonal array is used to acquire the wear data in a controlled way. An analysis of variance is employed to investigate the influence of four controlling parameters, viz., SiC content, normal load, sliding speed and sliding time on dry sliding wear of the composites. It is observed that SiC content, sliding speed and normal load significantly affect the dry sliding wear. The optimal combination of the four controlling parameters is also obtained for minimum wear. The microstructure study of worn surfaces indicates nature of wear to be mostly abrasive.

Significant genomic introgression from grey junglefowl(Gallus sonneratii)to domestic chickens(Gallus gallus domesticus)

Background Chicken is one of the most numerous and widely distributed species around the world,and many studies support the multiple ancestral origins of domestic chickens.The research regarding the yellow skin phenotype in domestic chickens(regulated by BCO2)likely originating from the grey junglefowl serves as crucial evidence for demonstrating the multiple origins of chickens.However,beyond the BCO2 gene region,much remains unknown about the introgression from the grey junglefowl into domestic chickens.Therefore,in this study,based on wholegenome data of 149 samples including 4 species of wild junglefowls and 13 local domestic chicken breeds,we explored the introgression events from the grey junglefowl to domestic chickens.Results We successfully detected introgression regions besides BCO2,including two associated with growth trait(IGFBP2 and TKT),one associated with angiogenesis(TIMP3)and two members of the heat shock protein family(HSPB2 and CRYAB).Our findings suggest that the introgression from the grey junglefowl may impact the growth performance of chickens.Furthermore,we revealed introgression events from grey junglefowl at the BCO2 region in multiple domestic chicken breeds,indicating a phenomenon where the yellow skin phenotype likely underwent strong selection and was retained.Additionally,our haplotype analysis shed light on BCO2 introgression event from different sources of grey junglefowl into domestic chickens,possibly suggesting multiple genetic flows between the grey junglefowl and domestic chickens.Conclusions In summary,our findings provide evidences of the grey junglefowl contributing to the genetic diversity of domestic chickens,laying the foundation for a deeper understanding of the genetic composition within domestic chickens,and offering new perspectives on the impact of introgression on domestic chickens.

Case Retrieval Strategy of Turning Process Based on Grey Relational Analysis

To solve the problem of long response time when users obtain suitable cutting parameters through the Internet based platform,a case-based reasoning framework is proposed.Specifically,a Hamming distance and Euclidean distance combined method is designed to measure the similarity of case features which have both numeric and category properties.In addition,AHP(Analytic Hierarchy Process)and entropy weight method are integrated to provide features weight,where both user preferences and comprehensive impact of the index have been concerned.Grey relation analysis is used to obtain the similarity of a new problem and alternative cases.Finally,a platform is also developed on Visual Studio 2015,and a case study is demonstrated to verify the practicality and efficiency of the proposed method.This method can obtain cutting parameters which is suitable without iterative calculation.Compared with the traditional PSO(Particle swarm optimization algorithm)and GA(Genetic algorithm),it can obtain faster response speed.This method can provide ideas for selecting processing parameters in industrial production.While guaranteeing the characteristic information is similar,this approach can select processing parameters which is the most appropriate for the production process and a lot of time can be saved.

To improve robustness of mechanical properties of semi-solid cast A356 alloy using taguchi design method

Mechanical properties of semi-solid casting are dependent on multiple processing parameters,and improper processing parameters will not only reduce mean data but also increase variations.The present study investigated the impact of parameters in slurry preparation and heat treatment on the yield strength and ductility of T6 heat-treated A356 Al-Si alloy using rapid slurry forming(RSF)semi-solid casting.The focus was primarily on the robustness of mechanical properties based on Taguchi design method.By analyzing signal-to-noise ratio and minimum value calculated from-3S,the optimum slurry preparation parameters and heat treatment parameters were determined to be no quench,enthalpy exchange material(EEM)temperature of 140℃,EEM-to-melt ratio of 6mass%,stirring time of 18 s,solution heat treated at 520℃ for 2 h,and ageing heat treated at 190℃ for 6 h.In a small batch validation,the-3S yield strength and-3S elongation reach 256.1 MPa and 5.03% respectively,showing a satisfactory robustness.The hardness and microstructure of heat-treated samples with the best and worst properties were characterized to gain insight into the underlying mechanisms affecting the mean value and variations of mechanical properties.

Design Optimization of a Self-circulated Hydrogen Cooling System for a PM Wind Generator Based on Taguchi Method

With the continuous improvement of permanent magnet(PM)wind generators'capacity and power density,the design of reasonable and efficient cooling structures has become a focus.This paper proposes a fully enclosed self-circulating hydrogen cooling structure for a originally forced-air-cooled direct-drive PM wind generator.The proposed hydrogen cooling system uses the rotor panel supports that hold the rotor core as the radial blades,and the hydrogen flow is driven by the rotating plates to flow through the axial and radial vents to realize the efficient cooling of the generator.According to the structural parameters of the cooling system,the Taguchi method is used to decouple the structural variables.The influence of the size of each cooling structure on the heat dissipation characteristic is analyzed,and the appropriate cooling structure scheme is determined.