International Journal of Experimental Design and Process Optimisation http://www.inderscience.com/browse/index.php?journalID=351&year=2011&vol=2&issue=4 Inderscience Publishers Ltd en-uk International Journal of Experimental Design and Process Optimisation 2040-2252 2040-2260 © 2011 Inderscience Publishers Ltd editor@inderscience.com https://www.inderscience.com/images/files/coverImgs/ijedpo_scoverijedpo.jpg http://www.inderscience.com/browse/index.php?journalID=351&year=2011&vol=2&issue=4 http://www.inderscience.com/link.php?id=43565 This paper deals with the use of Taguchi technique with fuzzy logic to optimise electrochemical micromachining (EMM) process with multiple quality characteristics. The truncated cone tip electrode produced the highest machining rate and the conical with rounded tip electrode produced holes with lesser overcut. Hence, achieving higher machining rate with lesser overcut can be considered as a multi-objective optimisation problem. The machining parameters (the tool electrode tip shape, machining voltage, pulse on-time, electrolyte concentration) are optimised with considerations of the multiple performance characteristics (machining rate and overcut). The experiments were conducted in the developed EMM set-up. The experimental results reveal that the conical with rounded electrode, machining voltage of 9 V, pulse on-time of 10 ms and electrolyte concentration of 0.35 mole/l is the optimum combination for higher machining rate and lesser overcut. In addition in-depth studies have also been made to examine the influence of tool electrode tip on the overcut through SEM micrographs of machined micro-hole. Applications of Taguchi technique with fuzzy logic to optimise an electrochemical micromachining process
R. Thanigaivelan; R.M. Arunachalam; J. Jerald; T. Niranjan
International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 283 - 298
This paper deals with the use of Taguchi technique with fuzzy logic to optimise electrochemical micromachining (EMM) process with multiple quality characteristics. The truncated cone tip electrode produced the highest machining rate and the conical with rounded tip electrode produced holes with lesser overcut. Hence, achieving higher machining rate with lesser overcut can be considered as a multi-objective optimisation problem. The machining parameters (the tool electrode tip shape, machining voltage, pulse on-time, electrolyte concentration) are optimised with considerations of the multiple performance characteristics (machining rate and overcut). The experiments were conducted in the developed EMM set-up. The experimental results reveal that the conical with rounded electrode, machining voltage of 9 V, pulse on-time of 10 ms and electrolyte concentration of 0.35 mole/l is the optimum combination for higher machining rate and lesser overcut. In addition in-depth studies have also been made to examine the influence of tool electrode tip on the overcut through SEM micrographs of machined micro-hole.

]]> 10.1504/IJEDPO.2011.043565 International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 283 - 298 R. Thanigaivelan; R.M. Arunachalam; J. Jerald; T. Niranjan Department of Mechanical Engineering, Muthayammal Engineering College, Rasipuram-637408, India. ' Department of Mechanical Engineering, Sona College of Technology, Salem-636005, India. ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620 015, India. ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620 015, India fuzzy logic Taguchi methods machining rate overcut stainless steel electrochemical micromachining electrochemical machining ECM multi-objective optimisation microholes. 2011-11-08T23:20:50-05:00 2 4 283 298 2011-11-08T23:20:50-05:00 http://www.inderscience.com/link.php?id=43566 Cathode ray tubes (CRTs) adopted in TV sets and computer monitors represent a consistent portion of waste electrical and electronic equipment (WEEE). In comparison with the recycling of WEEE such as refrigerators or washing machines, the recovery process for CRT containing devices is very difficult. CRTs are composed of four types of glass (panel, funnel, neck and frit seal) with different compositions. Furthermore, dangerous substances are contained within (i.e., lead, barium, strontium and fluorescent dust). Hence, the need to define robust processes for the design and implementation of efficient facilities for CRT cutting arises. This work describes steps guiding the design and the experimental optimal setting of a prototype facility for water-jet cutting of CRTs, in order to obtain recyclable high quality glass. Initially, a version of the cutting facility with manual movement of the cutting tool is set, in order to evaluate expectable cutting results. Subsequently, a detailed setting of automated movement of the cutting tool is carried out, in order to improve the quality of obtainable glass. As a consequence, a water-jet cutting facility which guarantees the cutting of high quality CRTs is finally set and a prototype is implemented. Design and experimental analysis of a prototype waterjet facility for cathode ray tube cutting: evidence from a case study
Rita Gamberini; Bianca Rimini; Luca Galloni; Andrea Baroni
International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 299 - 317
Cathode ray tubes (CRTs) adopted in TV sets and computer monitors represent a consistent portion of waste electrical and electronic equipment (WEEE). In comparison with the recycling of WEEE such as refrigerators or washing machines, the recovery process for CRT containing devices is very difficult. CRTs are composed of four types of glass (panel, funnel, neck and frit seal) with different compositions. Furthermore, dangerous substances are contained within (i.e., lead, barium, strontium and fluorescent dust). Hence, the need to define robust processes for the design and implementation of efficient facilities for CRT cutting arises. This work describes steps guiding the design and the experimental optimal setting of a prototype facility for water-jet cutting of CRTs, in order to obtain recyclable high quality glass. Initially, a version of the cutting facility with manual movement of the cutting tool is set, in order to evaluate expectable cutting results. Subsequently, a detailed setting of automated movement of the cutting tool is carried out, in order to improve the quality of obtainable glass. As a consequence, a water-jet cutting facility which guarantees the cutting of high quality CRTs is finally set and a prototype is implemented.

]]> 10.1504/IJEDPO.2011.043566 International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 299 - 317 Rita Gamberini; Bianca Rimini; Luca Galloni; Andrea Baroni Department of Engineering Sciences and Methods, University of Modena and Reggio Emilia, Via Amendola 2 Padiglione Morselli, 42100 Reggio Emilia, Italy. ' Department of Engineering Sciences and Methods, University of Modena and Reggio Emilia, Via Amendola 2 Padiglione Morselli, 42100 Reggio Emilia, Italy. ' Department of Engineering Sciences and Methods, University of Modena and Reggio Emilia, Via Amendola 2 Padiglione Morselli, 42100 Reggio Emilia, Italy. ' Department of Engineering Sciences and Methods, University of Modena and Reggio Emilia, Via Amendola 2 Padiglione Morselli, 42100 Reggio Emilia, Italy cathode ray tubes CRTs waterjet cutting prototype design of experiments DoE experimental design design process optimisation CRT cutting glass recycling product recovery end-of-life EOL products. 2011-11-08T23:20:50-05:00 2 4 299 317 2011-11-08T23:20:50-05:00 http://www.inderscience.com/link.php?id=43567 An algorithm is developed to deal with the discrete optimisation problem. The algorithm approximates any design continuous domain with finite number of discrete points and employs single and multi-level search to reach near-to-global optimum. Global optimisers are often expensive techniques. In single level search, one orthogonal array is used to model any given search domain. In multi-level search, two or more orthogonal arrays are coupled in series and used to model the search domain. The number of design levels are increased with the number of arrays via different coefficients. The tolerance synthesis problem with optimum process combination is revisited to compare our method with well-established algorithms such as simulated annealing (SA) and sequential quadratic programming (SQP). The effect of algorithm parameters: different structure combinations, reducing move factors, weighing factors and column assignments on optimum for single and multi-level search are investigated. Results indicate the capability of the approach to reach near-to-global optimum in about 5.20%-19.5% of time taken by other methods which justifies the use of the developed algorithms unless global optimisers are specially needed. Tolerance optimisation problem using a near-to-global optimum
Mohamed H. Gadallah
International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 318 - 335
An algorithm is developed to deal with the discrete optimisation problem. The algorithm approximates any design continuous domain with finite number of discrete points and employs single and multi-level search to reach near-to-global optimum. Global optimisers are often expensive techniques. In single level search, one orthogonal array is used to model any given search domain. In multi-level search, two or more orthogonal arrays are coupled in series and used to model the search domain. The number of design levels are increased with the number of arrays via different coefficients. The tolerance synthesis problem with optimum process combination is revisited to compare our method with well-established algorithms such as simulated annealing (SA) and sequential quadratic programming (SQP). The effect of algorithm parameters: different structure combinations, reducing move factors, weighing factors and column assignments on optimum for single and multi-level search are investigated. Results indicate the capability of the approach to reach near-to-global optimum in about 5.20%-19.5% of time taken by other methods which justifies the use of the developed algorithms unless global optimisers are specially needed.

]]> 10.1504/IJEDPO.2011.043567 International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 318 - 335 Mohamed H. Gadallah Department of Mechanical Design and Production, Faculty of Engineering, Cairo University, 12613, Egypt tolerance optimisation design of experiments DOE near-to-global optimum discrete optimisation tolerance synthesis. 2011-11-08T23:20:50-05:00 2 4 318 335 2011-11-08T23:20:50-05:00 http://www.inderscience.com/link.php?id=43568 This study investigates the optimisation of process parameters of micro electric discharge machining (micro-EDM) for stainless steel grade 316 (SS 316) on the machining characteristics using the Grey relational analysis (GRA) method. Experiments based on the orthogonal array (OA) of Taguchi method have been carried out. The multi-response optimisation of the process parameters viz. material removal rate (MRR), tool wear rate (TWR), Diametral OverCut (DOC) and Taper (T) has been performed. By analysing the Grey relational grade matrix, the degree of influence of each process parameter on individual quality target can be measured. The current is identified to be the most influential factor of the MRR, TWR and the T. In addition, the analysis of variance (ANOVA) is also carried out to identify the most significant factor. In depth studies have also been made to examine the influence of various process parameters through SEM micrographs of machined micro-hole. Experimental investigations and optimisation of process parameters in micro-EDM with multiple performance characteristics
N. Natarajan; R.M. Arunachalam
International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 336 - 356
This study investigates the optimisation of process parameters of micro electric discharge machining (micro-EDM) for stainless steel grade 316 (SS 316) on the machining characteristics using the Grey relational analysis (GRA) method. Experiments based on the orthogonal array (OA) of Taguchi method have been carried out. The multi-response optimisation of the process parameters viz. material removal rate (MRR), tool wear rate (TWR), Diametral OverCut (DOC) and Taper (T) has been performed. By analysing the Grey relational grade matrix, the degree of influence of each process parameter on individual quality target can be measured. The current is identified to be the most influential factor of the MRR, TWR and the T. In addition, the analysis of variance (ANOVA) is also carried out to identify the most significant factor. In depth studies have also been made to examine the influence of various process parameters through SEM micrographs of machined micro-hole.

]]> 10.1504/IJEDPO.2011.043568 International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 336 - 356 N. Natarajan; R.M. Arunachalam Department of Mechanical Engineering, Muthayammal Engineering College, Rasipuram 637 408, Namakkal District, Tamil Nadu, India. ' Department of Mechanical Engineering, Sona College of Technology, Salem 636 005, Tamilnadu, India grey relational analysis GRA optimisation micro-EDM analysis of variance ANOVA white layer Taguchi methods microholes electro-discharge machining electrical discharge machining EDM material removal rate MRR tool wear overcut taper stainless steel multi-response optimisation. 2011-11-08T23:20:50-05:00 2 4 336 356 2011-11-08T23:20:50-05:00 http://www.inderscience.com/link.php?id=43569 This paper deals with the optimisation of the deep cryogenic treatment process for 21-4N valve steel to maximise the tensile strength, hardness and wear resistance using Grey-Taguchi method. The factors considered for the optimisation are the cooling rate, soaking temperature, soaking period and aging temperature, each at three different levels. Nine experimental trials based on the L<SUB align=right>9 (3<SUP align=right>4</SUP>) orthogonal array were conducted. The analysis of variance (ANOVA) is performed to identify the significant contribution of parameters. A confirmation test is conducted to validate the test result. The improvement in tensile strength, hardness and wear resistance from the untreated samples to the deep-cryo treated samples at the optimised treatment condition are 11.87%, 15.32% and 27.8% respectively. The result of the confirmation experiment shows that the responses are improved simultaneously through the optimal combination of the deep cryogenic treatment parameters obtained from the proposed method. Multi-response optimisation of the deep cryogenic treatment for 21-4N valve steel
M. Arockia Jaswin; D. Mohan Lal
International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 357 - 372
This paper deals with the optimisation of the deep cryogenic treatment process for 21-4N valve steel to maximise the tensile strength, hardness and wear resistance using Grey-Taguchi method. The factors considered for the optimisation are the cooling rate, soaking temperature, soaking period and aging temperature, each at three different levels. Nine experimental trials based on the L<SUB align=right>9 (3<SUP align=right>4</SUP>) orthogonal array were conducted. The analysis of variance (ANOVA) is performed to identify the significant contribution of parameters. A confirmation test is conducted to validate the test result. The improvement in tensile strength, hardness and wear resistance from the untreated samples to the deep-cryo treated samples at the optimised treatment condition are 11.87%, 15.32% and 27.8% respectively. The result of the confirmation experiment shows that the responses are improved simultaneously through the optimal combination of the deep cryogenic treatment parameters obtained from the proposed method.

]]> 10.1504/IJEDPO.2011.043569 International Journal of Experimental Design and Process Optimisation, Vol. 2, No. 4 (2011) pp. 357 - 372 M. Arockia Jaswin; D. Mohan Lal Department of Mechanical Engineering, Aksheyaa College of Engineering, Puludivakkam, Chennai 603 314, India. ' Department of Mechanical Engineering, College of Engineering Guindy, Anna University Chennai, Chennai 600 025, India valve steel deep cryogenic treatment DCT Taguchi methods grey relational analysis GRA analysis of variance ANOVA tensile strength hardness wear resistance cooling rate soaking temperature soaking period aging temperature. 2011-11-08T23:20:50-05:00 2 4 357 372 2011-11-08T23:20:50-05:00