Melhoria da qualidade de um processo de usinagem utilizando as técnicas de avaliação de Taguchi

Delivering to the customers a product or service with the expected quality associated to the huge competitiveness that exists in the market nowadays, has been making organizations increasingly focus on quality planning using techniques which are directed towards the continuous improvement process and production optimization. Thus, this paper aims to improve a machining process using the techniques of experimental design to the optimization and this also includes the analysis of the measurement system. For this purpose, the alloy Nimonic 80A, a nickel base superalloy, was used in the process due to its widespread use for high temperatures, applying this study the robust method proposed by Genichi Taguchi, determining the influence of the factors considered input variables, cutting speed, feed rate, depth of cut, type of tool, lubrication, and material hardness, in the output or response variable, surface roughness, concluding with the use of Taguchi orthogonal array L16 and by analysis of ANOVA that the factor feed rate is significant and offers greater effect on the response variable studied, should be set to 0,12mm/rev. Moreover, the factor type of tool has more influence on the process when compared to other factors, being CP250 the one more suitable to the process. Lastly, the interaction feed rate x cutting speed provides greater significance in the process regarding to surface roughness variable, being the best match between them 0,12mm/rev to the feed rate and 90m/min to the cutting speed. In order to evaluate the measurement system, it was applied the repeatability and reproducibility method (R&R), through which we saw that the system needs improvement (R & R = 88.04% >>> 30%) as the value found in the study was well above compared to the one that classifies the system as inappropriate

Aplicação nas indústrias de processos de técnicas modernas de controle de qualidade

Nó primeiro capítulo, faço com um relato da evolução do controle de qualidade nos últimos 60 anos. Descrevo as diversas escolas de controle de qualidade, suas tendências, bem como a evolução da tecnologia empregada. A partir desta visão panorâmica inicial, descrevo, nos capítulos seguintes, as técnicas modernas de controle de qualidade, com ênfase nas técnicas de engenharia da qualidade e de delineamento de experimentos, muito usadas por Genichi Taguchi. Abordo também as características e necessidades dá qualidade nas indústrias de processos. Mostro as razões pela qual os métodos tradicionais de controle de qualidade nem sempre foram bem sucedidos, quando implementados nas indústrias químicas de modo geral.

Can we learn more from fewer seeds?

The vital role that 'design of experiment' (DOE) plays when investigating dormancy, germination and potentially influential factors is discussed. The Taguchi analysis, developed by Dr. Genichi Taguchi, is a special application and analysis of the fractional factorial aimed at achieving maximum information from minimum effort and resources.

Taguchi optimized synthesis of graphene films by copper catalyzed ethanol decomposition

Taguchi method is for the first time applied to optimize the synthesis of graphene films by copper-catalyzed decomposition of ethanol. In order to find the most appropriate experimental conditions for the realization of thin high-grade films, six experiments suitably designed and performed. The influence of temperature (1000–1070 °C) and synthesis duration (1–30 min) and hydrogen flow (0–100 sccm) on the number of graphene layers and defect density in the graphitic lattice was ranked by monitoring the intensity of the 2D- and D-bands relative to the G-band in the Raman spectra. After critical examination and adjusting of the conditions predicted to give optimal results, a continuous film consisting of 2–4 nearly defect-free graphene layers was obtained.

Optimization of degree of sphericity of primary phase during cooling slope casting of A356 Al alloy: Taguchi method and regression analysis

The present work presents the results of experimental investigation of semi-solid rheocasting of A356 Al alloy using a cooling slope. The experiments have been carried out following Taguchi method of parameter design (orthogonal array of L-9 experiments). Four key process variables (slope angle, pouring temperature, wall temperature, and length of travel of the melt) at three different levels have been considered for the present experimentation. Regression analysis and analysis of variance (ANOVA) has also been performed to develop a mathematical model for degree of sphericity evolution of primary alpha-Al phase and to find the significance and percentage contribution of each process variable towards the final outcome of degree of sphericity, respectively. The best processing condition has been identified for optimum degree of sphericity (0.83) as A(3), B-3, C-2, D-1 i.e., slope angle of 60 degrees, pouring temperature of 650 degrees C, wall temperature 60 degrees C, and 500 mm length of travel of the melt, based on mean response and signal to noise ratio (SNR). ANOVA results shows that the length of travel has maximum impact on degree of sphericity evolution. The predicted sphericity obtained from the developed regression model and the values obtained experimentally are found to be in good agreement with each other. The sphericity values obtained from confirmation experiment, performed at 95% confidence level, ensures that the optimum result is correct and also the confirmation experiment values are within permissible limits. (c) 2014 Elsevier Ltd. All rights reserved.

Parameter studies of fibre laser micro-welding of AISI 316L using Taguchi method

This paper discusses the application of the Taguchi experimental design approach in optimizing the key process parameters for micro-welding of thin AISI 316L foil using the 100W CW fibre laser. A L16 Taguchi experiment was conducted to systematically understand how the power, scanning velocity, focus position, gas flow rate and type of shielding gas affect the bead dimensions. The welds produced in the L16 Taguchi experiment was mainly of austenite cellular-dendrite structure with an average grain size of 5µm. An exact penetration weld with the largest penetration to fusion width ratio was obtained. Among those process parameters, the interaction between power and scanning velocity presented the strongest effect to the penetration to fusion width ratio and the power was found to be the predominantly important factor that drives the interaction with other factors to appreciably affect the bead dimensions.

Parameter study on laser welding of nitinol wire by Taguchi method

A L27 Taguchi experiment was done to investigate the effect of laser power, welding time, laser mode (CW and two pulsed modes), focus position, and their possible interactions on the weld-bead aspect ratio of laser-welded NiTi wires by using a 100W fibre laser. The optimized parameter setting to produce the full penetrated weldment with minimum welding defects is successfully determined in the Taguchi experiment. The laser mode is found to be the most important parameter that directly controls the weld-bead aspect ratio. The focus position is the secondly important parameter for the laser welding of NiTi wires. Strong interaction between the power and focus position is found in the Taguchi experiment. The optimized weldment produced by the Taguchi experiment is mainly of columnar dendritic structure in the weld zone (WZ) with the size of 1-3µm, while the HAZ exhibits equiaxed grain structure with the size of 5-10µm. The Vickers micro-hardness test indicted that the WZ and HAZ in the weldment are softened to certain extends after fibre laser welding.

Parameter Optimization on Laser Welding of NiTi Wires by Taguchi Method

In this research, a preliminary study was done to find out the initial parameter window to obtain the full-penetrated NiTi weldment. A L27 Taguchi experiment was then carried out to statistically study the effects of the welding parameters and their possible interactions on the weld bead aspect ratio (or penetration over fuse-zone width ratio), and to determine the optimized parameter settings to produce the full-penetrated weldment with desirable aspect ratio. From the statistical results in the Taguchi experiment, the laser mode was found to be the most important factor that substantially affects the aspect ratio. Strong interaction between the power and focus position was found in the Taguchi experiment. The optimized weldment was mainly of columnar dendritic structure in the weld zone (WZ), while the HAZ exhibited equiaxed grain structure. The XRD and DSC results showed that the WZ remained the B2 austenite structure without any precipitates, but with a significant decrease of phase transformation temperatures. The results in the micro-hardness and tensile tests indicated that the mechanical properties of NiTi were decreased to a certain extent after fibre laser welding.

Taguchi optimisation approach for production of activated carbon from phosphoric acid impregnated palm kernel shell by microwave heating

Taguchi method was applied to investigate the optimal operating conditions in the preparation of activated carbon using palm kernel shell with quadruple control factors: irradiation time, microwave power, concentration of phosphoric acid as impregnation substance and impregnation ratio between acid and palm kernel shell. The best combination of the control factors as obtained by applying Taguchi method was microwave power of 800 W, irradiation time of 17 min, impregnation ratio of 2, and acid concentration of 85%. The noise factor (particle size of raw material) was considered in a separate outer array, which had no effect on the quality of the activated carbon as confirmed by t-test. Activated carbon prepared at optimum combination of control factors had high BET surface area of 1,473.55 m² g-1 and high porosity. The adsorption equilibrium and kinetic data can satisfactorily be described by the Langmuir isotherm and a pseudo-second-order kinetic model, respectively. The maximum adsorbing capacity suggested by the Langmuir model was 1000 mg g-1.