International Science Index

24
10011019
Optimization of Surface Finish in Milling Operation Using Live Tooling via Taguchi Method
Abstract:

The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L9 orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.

Paper Detail
361
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23
10010062
Optimization of Two Quality Characteristics in Injection Molding Processes via Taguchi Methodology
Abstract:

The main objective of this research is to optimize tensile strength and dimensional accuracy in injection molding processes using Taguchi Parameter Design. An L16 orthogonal array (OA) is used in Taguchi experimental design with five control factors at four levels each and with non-controllable factor vibration. A total of 32 experiments were designed to obtain the optimal parameter setting for the process. The optimal parameters identified for the shrinkage are shot volume, 1.7 cubic inch (A4); mold term temperature, 130 ºF (B1); hold pressure, 3200 Psi (C4); injection speed, 0.61 inch3/sec (D2); and hold time of 14 seconds (E2). The optimal parameters identified for the tensile strength are shot volume, 1.7 cubic inch (A4); mold temperature, 160 ºF (B4); hold pressure, 3100 Psi (C3); injection speed, 0.69 inch3/sec (D4); and hold time of 14 seconds (E2). The Taguchi-based optimization framework was systematically and successfully implemented to obtain an adjusted optimal setting in this research. The mean shrinkage of the confirmation runs is 0.0031%, and the tensile strength value was found to be 3148.1 psi. Both outcomes are far better results from the baseline, and defects have been further reduced in injection molding processes.

Paper Detail
403
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22
10008824
Optimization of Surface Roughness in Turning Process Utilizing Live Tooling via Taguchi Methodology
Abstract:

The objective of this research is to optimize the process of cutting cylindrical workpieces utilizing live tooling on a HAAS ST-20 lathe. Surface roughness (Ra) has been investigated as the indicator of quality characteristics for machining process. Aluminum alloy was used to conduct experiments due to its wide range usages in engineering structures and components where light weight or corrosion resistance is required. In this study, Taguchi methodology is utilized to determine the effects that each of the parameters has on surface roughness (Ra). A total of 18 experiments of each process were designed according to Taguchi’s L9 orthogonal array (OA) with four control factors at three levels of each and signal-to-noise ratios (S/N) were computed with Smaller the better equation for minimizing the system. The optimal parameters identified for the surface roughness of the turning operation utilizing live tooling were a feed rate of 3 inches/min(A3); a spindle speed of 1300 rpm(B3); a 2-flute titanium nitrite coated 3/8” endmill (C1); and a depth of cut of 0.025 inches (D2). The mean surface roughness of the confirmation runs in turning operation was 8.22 micro inches. The final results demonstrate that Taguchi methodology is a sufficient way of process improvement in turning process on surface roughness.

Paper Detail
469
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21
10007983
Taguchi-Based Six Sigma Approach to Optimize Surface Roughness for Milling Processes
Abstract:

This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Paper Detail
676
downloads
20
10007986
Design of Bayesian MDS Sampling Plan Based on the Process Capability Index
Abstract:

In this paper, a variable multiple dependent state (MDS) sampling plan is developed based on the process capability index using Bayesian approach. The optimal parameters of the developed sampling plan with respect to constraints related to the risk of consumer and producer are presented. Two comparison studies have been done. First, the methods of double sampling model, sampling plan for resubmitted lots and repetitive group sampling (RGS) plan are elaborated and average sample numbers of the developed MDS plan and other classical methods are compared. A comparison study between the developed MDS plan based on Bayesian approach and the exact probability distribution is carried out.

Paper Detail
635
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19
10005426
Milling Simulations with a 3-DOF Flexible Planar Robot
Abstract:
Manufacturing technologies are becoming continuously more diversified over the years. The increasing use of robots for various applications such as assembling, painting, welding has also affected the field of machining. Machining robots can deal with larger workspaces than conventional machine-tools at a lower cost and thus represent a very promising alternative for machining applications. Furthermore, their inherent structure ensures them a great flexibility of motion to reach any location on the workpiece with the desired orientation. Nevertheless, machining robots suffer from a lack of stiffness at their joints restricting their use to applications involving low cutting forces especially finishing operations. Vibratory instabilities may also happen while machining and deteriorate the precision leading to scrap parts. Some researchers are therefore concerned with the identification of optimal parameters in robotic machining. This paper continues the development of a virtual robotic machining simulator in order to find optimized cutting parameters in terms of depth of cut or feed per tooth for example. The simulation environment combines an in-house milling routine (DyStaMill) achieving the computation of cutting forces and material removal with an in-house multibody library (EasyDyn) which is used to build a dynamic model of a 3-DOF planar robot with flexible links. The position of the robot end-effector submitted to milling forces is controlled through an inverse kinematics scheme while controlling the position of its joints separately. Each joint is actuated through a servomotor for which the transfer function has been computed in order to tune the corresponding controller. The output results feature the evolution of the cutting forces when the robot structure is deformable or not and the tracking errors of the end-effector. Illustrations of the resulting machined surfaces are also presented. The consideration of the links flexibility has highlighted an increase of the cutting forces magnitude. This proof of concept will aim to enrich the database of results in robotic machining for potential improvements in production.
Paper Detail
987
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18
10005955
Optimal Bayesian Control of the Proportion of Defectives in a Manufacturing Process
Abstract:
In this paper, we present a model and an algorithm for the calculation of the optimal control limit, average cost, sample size, and the sampling interval for an optimal Bayesian chart to control the proportion of defective items produced using a semi-Markov decision process approach. Traditional p-chart has been widely used for controlling the proportion of defectives in various kinds of production processes for many years. It is well known that traditional non-Bayesian charts are not optimal, but very few optimal Bayesian control charts have been developed in the literature, mostly considering finite horizon. The objective of this paper is to develop a fast computational algorithm to obtain the optimal parameters of a Bayesian p-chart. The decision problem is formulated in the partially observable framework and the developed algorithm is illustrated by a numerical example.
Paper Detail
791
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17
10004983
Minimization Entropic Applied to Rotary Dryers to Reduce the Energy Consumption
Abstract:
The drying process is an important operation in the chemical industry and it is widely used in the food, grain industry and fertilizer industry. However, for demanding a considerable consumption of energy, such a process requires a deep energetic analysis in order to reduce operating costs. This paper deals with thermodynamic optimization applied to rotary dryers based on the entropy production minimization, aiming at to reduce the energy consumption. To do this, the mass, energy and entropy balance was used for developing a relationship that represents the rate of entropy production. The use of the Second Law of Thermodynamics is essential because it takes into account constraints of nature. Since the entropy production rate is minimized, optimals conditions of operations can be established and the process can obtain a substantial gain in energy saving. The minimization strategy had been led using classical methods such as Lagrange multipliers and implemented in the MATLAB platform. As expected, the preliminary results reveal a significant energy saving by the application of the optimal parameters found by the procedure of the entropy minimization It is important to say that this method has shown easy implementation and low cost.
Paper Detail
1023
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16
10001348
Evaluation of Heterogeneity of Paint Coating on Metal Substrate Using Laser Infrared Thermography and Eddy Current
Abstract:
Non contact evaluation of the thickness of paint coatings can be attempted by different destructive and nondestructive methods such as cross-section microscopy, gravimetric mass measurement, magnetic gauges, Eddy current, ultrasound or terahertz. Infrared thermography is a nondestructive and non-invasive method that can be envisaged as a useful tool to measure the surface thickness variations by analyzing the temperature response. In this paper, the thermal quadrupole method for two layered samples heated up with a pulsed excitation is firstly used. By analyzing the thermal responses as a function of thermal properties and thicknesses of both layers, optimal parameters for the excitation source can be identified. Simulations show that a pulsed excitation with duration of ten milliseconds allows obtaining a substrate-independent thermal response. Based on this result, an experimental setup consisting of a near-infrared laser diode and an Infrared camera was next used to evaluate the variation of paint coating thickness between 60 μm and 130 μm on two samples. Results show that the parameters extracted for thermal images are correlated with the estimated thicknesses by the Eddy current methods. The laser pulsed thermography is thus an interesting alternative nondestructive method that can be moreover used for nonconductive substrates.
Paper Detail
1752
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15
10000488
Practical Application of Simulation of Business Processes
Abstract:

Company managers are always looking for more and more opportunities to succeed in today's fiercely competitive market. To maintain your place among the successful companies on the market today or to come up with a revolutionary business idea is much more difficult than before. Each new or improved method, tool, or approach that can improve the functioning of business processes or even of the entire system is worth checking and verification. The use of simulation in the design of manufacturing systems and their management in practice is one of the ways without increased risk, which makes it possible to find the optimal parameters of manufacturing processes and systems. The paper presents an example of use of simulation for solution of the bottleneck problem in the concrete company.

Paper Detail
2622
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14
9998700
Optimal Design for SARMA(P,Q)L Process of EWMA Control Chart
Authors:
Abstract:

The main goal of this paper is to study Statistical Process Control (SPC) with Exponentially Weighted Moving Average (EWMA) control chart when observations are serially-correlated. The characteristic of control chart is Average Run Length (ARL) which is the average number of samples taken before an action signal is given. Ideally, an acceptable ARL of in-control process should be enough large, so-called (ARL0). Otherwise it should be small when the process is out-of-control, so-called Average of Delay Time (ARL1) or a mean of true alarm. We find explicit formulas of ARL for EWMA control chart for Seasonal Autoregressive and Moving Average processes (SARMA) with Exponential white noise. The results of ARL obtained from explicit formula and Integral equation are in good agreement. In particular, this formulas for evaluating (ARL0) and (ARL1) be able to get a set of optimal parameters which depend on smoothing parameter (λ) and width of control limit (H) for designing EWMA chart with minimum of (ARL1).

Paper Detail
1704
downloads
13
9997967
Gluten-Free Cookies Enriched with Blueberry Pomace: Optimization of Baking Process
Abstract:

With the aim of improving nutritional profile and antioxidant capacity of gluten-free cookies, blueberry pomace, by-product of juice production, was processed into a new food ingredient by drying and grinding and used for a gluten-free cookie formulation. Since the quality of a baked product is highly influenced by the baking conditions, the objective of this work was to optimize the baking time and thickness of dough pieces, by applying Response Surface Methodology (RSM) in order to obtain the best technological quality of the cookies. The experiments were carried out according to a Central Composite Design (CCD) by selecting the dough thickness and baking time as independent variables, while hardness, color parameters (L*, a* and b* values), water activity, diameter and short/long ratio were response variables. According to the results of RSM analysis, the baking time of 13.74min and dough thickness of 4.08mm was found to be the optimal for the baking temperature of 170°C. As similar optimal parameters were obtained by previously conducted experiment based on sensory analysis, response surface methodology (RSM) can be considered as a suitable approach to optimize the baking process.

Paper Detail
2172
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12
9997539
Optimum Parameter of a Viscous Damper for Seismic and Wind Vibration
Abstract:

Determination of optimal parameters of a passive  control system device is the primary objective of this study.  Expanding upon the use of control devices in wind and earthquake  hazard reduction has led to development of various control systems.  The advantage of non-linearity characteristics in a passive control  device and the optimal control method using LQR algorithm are  explained in this study. Finally, this paper introduces a simple  approach to determine optimum parameters of a nonlinear viscous  damper for vibration control of structures. A MATLAB program is  used to produce the dynamic motion of the structure considering the  stiffness matrix of the SDOF frame and the non-linear damping  effect. This study concluded that the proposed system (variable  damping system) has better performance in system response control  than a linear damping system. Also, according to the energy  dissipation graph, the total energy loss is greater in non-linear  damping system than other systems.

 

Paper Detail
3250
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11
16091
Optimal Parameters of Double Moving Average Control Chart
Authors:
Abstract:
The objective of this paper is to present explicit analytical formulas for evaluating important characteristics of Double Moving Average control chart (DMA) for Poisson distribution. The most popular characteristics of a control chart are Average Run Length ( 0 ARL ) - the mean of observations that are taken before a system is signaled to be out-of control when it is actually still incontrol, and Average Delay time ( 1 ARL ) - mean delay of true alarm times. An important property required of 0 ARL is that it should be sufficiently large when the process is in-control to reduce a number of false alarms. On the other side, if the process is actually out-ofcontrol then 1 ARL should be as small as possible. In particular, the explicit analytical formulas for evaluating 0 ARL and 1 ARL be able to get a set of optimal parameters which depend on a width of the moving average ( w ) and width of control limit ( H ) for designing DMA chart with minimum of 1 ARL
Paper Detail
1981
downloads
10
3122
Evaluation of a PSO Approach for Optimum Design of a First-Order Controllers for TCP/AQM Systems
Abstract:
This paper presents a Particle Swarm Optimization (PSO) method for determining the optimal parameters of a first-order controller for TCP/AQM system. The model TCP/AQM is described by a second-order system with time delay. First, the analytical approach, based on the D-decomposition method and Lemma of Kharitonov, is used to determine the stabilizing regions of a firstorder controller. Second, the optimal parameters of the controller are obtained by the PSO algorithm. Finally, the proposed method is implemented in the Network Simulator NS-2 and compared with the PI controller.
Paper Detail
1501
downloads
9
4149
Characterization of Fabricated A 384.1-MgO Based Metal Matrix Composite and Optimization of Tensile Strength using Taguchi Techniques
Abstract:
The present work consecutively on synthesis and characterization of composites, Al/Al alloy A 384.1 as matrix in which the main ingredient as Al/Al-5% MgO alloy based metal matrix composite. As practical implications the low cost processing route for the fabrication of Al alloy A 384.1 and operational difficulties of presently available manufacturing processes based in liquid manipulation methods. As all new developments, complete understanding of the influence of processing variables upon the final quality of the product. And the composite is applied comprehensively to the acquaintance for achieving superiority of information concerning the specific heat measurement of a material through the aid of thermographs. Products are evaluated concerning relative particle size and mechanical behavior under tensile strength. Furthermore, Taguchi technique was employed to examine the experimental optimum results are achieved, owing to effectiveness of this approach.
Paper Detail
1384
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8
5557
Parametric Analysis in the Electronic Sensor Frequency Adjustment Process
Abstract:
The use of electronic sensors in the electronics industry has become increasingly popular over the past few years, and it has become a high competition product. The frequency adjustment process is regarded as one of the most important process in the electronic sensor manufacturing process. Due to inaccuracies in the frequency adjustment process, up to 80% waste can be caused due to rework processes; therefore, this study aims to provide a preliminary understanding of the role of parameters used in the frequency adjustment process, and also make suggestions in order to further improve performance. Four parameters are considered in this study: air pressure, dispensing time, vacuum force, and the distance between the needle tip and the product. A full factorial design for experiment 2k was considered to determine those parameters that significantly affect the accuracy of the frequency adjustment process, where a deviation in the frequency after adjustment and the target frequency is expected to be 0 kHz. The experiment was conducted on two levels, using two replications and with five center-points added. In total, 37 experiments were carried out. The results reveal that air pressure and dispensing time significantly affect the frequency adjustment process. The mathematical relationship between these two parameters was formulated, and the optimal parameters for air pressure and dispensing time were found to be 0.45 MPa and 458 ms, respectively. The optimal parameters were examined by carrying out a confirmation experiment in which an average deviation of 0.082 kHz was achieved.
Paper Detail
1104
downloads
7
6750
Application of Femtosecond Laser pulses for Nanometer Accuracy Profiling of Quartz and Diamond Substrates and for Multi-Layered Targets and Thin-Film Conductors Processing
Abstract:
Research results and optimal parameters investigation of laser cut and profiling of diamond and quartz substrates by femtosecond laser pulses are presented. Profiles 10 μm in width, ~25 μm in depth and several millimeters long were made. Investigation of boundaries quality has been carried out with the use of AFM «Vecco». Possibility of technological formation of profiles and micro-holes in diamond and quartz substrates with nanometer-scale boundaries is shown. Experimental results of multilayer dielectric cover treatment are also presented. Possibility of precise upper layer (thickness of 70–140 nm) removal is demonstrated. Processes of thin metal film (60 nm and 350 nm thick) treatment are considered. Isolation tracks (conductance ~ 10-11 S) 1.6–2.5 μm in width in conductive metal layers are formed.
Paper Detail
1258
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6
6622
Quantitative Determination of Trace Elements in Some Oriental Herb Products
Abstract:
The quantitative determination of several trace elements (Cr, As, Se, Cd, Hg, Pb) existing as inorganic impurities in some oriental herb-products such as Lingzhi Mushroom capsules, Philamin powder, etc using ICP-MS has been studied. Various instrumental parameters such as power, gas flow rate, sample depth, as well as the concentration of nitric acid and thick background due to high concentration of possible interferences on the determination of these above-mentioned elements was investigated and the optimum working conditions of the sample measurement on ICP-MS (Agilent-7500a) were reported. Appropriate isotope internal standards were also used to improve the accuracy of mercury determination. Optimal parameters for sampling digestion were also investigated. The recovery of analytical procedure was examined by using a Certified Reference Material (IAEA-CRM 359). The recommended procedure was then applied for the quantitative determination of Cr, As, Se, Cd, Hg, Pb in Lingzhi Mushroom capsule, and Philamine powder samples. The reproducibility of sample measurement (average value between 94 and 102%) and the uncertainty of analytical data (less than 20%) are acceptable.
Paper Detail
3374
downloads
5
1583
Genetic Algorithms and Kernel Matrix-based Criteria Combined Approach to Perform Feature and Model Selection for Support Vector Machines
Authors:
Abstract:
Feature and model selection are in the center of attention of many researches because of their impact on classifiers- performance. Both selections are usually performed separately but recent developments suggest using a combined GA-SVM approach to perform them simultaneously. This approach improves the performance of the classifier identifying the best subset of variables and the optimal parameters- values. Although GA-SVM is an effective method it is computationally expensive, thus a rough method can be considered. The paper investigates a joined approach of Genetic Algorithm and kernel matrix criteria to perform simultaneously feature and model selection for SVM classification problem. The purpose of this research is to improve the classification performance of SVM through an efficient approach, the Kernel Matrix Genetic Algorithm method (KMGA).
Paper Detail
1258
downloads
4
12931
Performance of an Electrocoagulation Process in Treating Direct Dye: Batch and Continuous Upflow Processes
Abstract:
This study presents an investigation of electrochemical variables and an application of the optimal parameters in operating a continuous upflow electrocoagulation reactor in removing dye. Direct red 23, which is azo-based, was used as a representative of direct dyes. First, a batch mode was employed to optimize the design parameters: electrode type, electrode distance, current density and electrocoagulation time. The optimal parameters were found to be iron anode, distance between electrodes of 8 mm and current density of 30 A·m-2 with contact time of 5 min. The performance of the continuous upflow reactor with these parameters was satisfactory, with >95% color removal and energy consumption in the order of 0.6-0.7 kWh·m-3.
Paper Detail
2677
downloads
3
3000
Optimized Calculation of Hourly Price Forward Curve (HPFC)
Abstract:
This paper examines many mathematical methods for molding the hourly price forward curve (HPFC); the model will be constructed by numerous regression methods, like polynomial regression, radial basic function neural networks & a furrier series. Examination the models goodness of fit will be done by means of statistical & graphical tools. The criteria for choosing the model will depend on minimize the Root Mean Squared Error (RMSE), using the correlation analysis approach for the regression analysis the optimal model will be distinct, which are robust against model misspecification. Learning & supervision technique employed to determine the form of the optimal parameters corresponding to each measure of overall loss. By using all the numerical methods that mentioned previously; the explicit expressions for the optimal model derived and the optimal designs will be implemented.
Paper Detail
3936
downloads
2
2203
Solving Bus Terminal Location Problem Using Genetic Algorithm
Abstract:
Bus networks design is an important problem in public transportation. The main step to this design, is determining the number of required terminals and their locations. This is an especial type of facility location problem, a large scale combinatorial optimization problem that requires a long time to be solved. The genetic algorithm (GA) is a search and optimization technique which works based on evolutionary principle of natural chromosomes. Specifically, the evolution of chromosomes due to the action of crossover, mutation and natural selection of chromosomes based on Darwin's survival-of-the-fittest principle, are all artificially simulated to constitute a robust search and optimization procedure. In this paper, we first state the problem as a mixed integer programming (MIP) problem. Then we design a new crossover and mutation for bus terminal location problem (BTLP). We tested the different parameters of genetic algorithm (for a sample problem) and obtained the optimal parameters for solving BTLP with numerical try and error.
Paper Detail
2007
downloads
1
15166
Analysis of Genotype Size for an Evolvable Hardware System
Abstract:

The evolution of logic circuits, which falls under the heading of evolvable hardware, is carried out by evolutionary algorithms. These algorithms are able to automatically configure reconfigurable devices. One of main difficulties in developing evolvable hardware with the ability to design functional electrical circuits is to choose the most favourable EA features such as fitness function, chromosome representations, population size, genetic operators and individual selection. Until now several researchers from the evolvable hardware community have used and tuned these parameters and various rules on how to select the value of a particular parameter have been proposed. However, to date, no one has presented a study regarding the size of the chromosome representation (circuit layout) to be used as a platform for the evolution in order to increase the evolvability, reduce the number of generations and optimize the digital logic circuits through reducing the number of logic gates. In this paper this topic has been thoroughly investigated and the optimal parameters for these EA features have been proposed. The evolution of logic circuits has been carried out by an extrinsic evolvable hardware system which uses (1+λ) evolution strategy as the core of the evolution.

Paper Detail
1375
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