注塑成型工艺参数对制品体收缩率变化的影响及工艺参数优化

结合CAE及Taguchi DOE技术研究工艺参数对注塑制品体收缩率变化(制品中体收缩率的最大值与最小值的差值)的影响并获得优化的工艺参数以使制品的体收缩率变化最小。文中采用L9(3^4)正交矩阵进行实验,并研究了各个参数对制品体收缩率变化的影响程度,对于所选参数,保压压力和模具温度对注塑制品的体收缩率变化的影响较大。     

Application of Taguchi approach to optimize of FSSW parameters on joint properties of dissimilar AA2024-T3 and AA5754-H22 aluminum alloys

In this study, the effect of plate positioning on mechanical properties of dissimilar lap joints was investigated by friction stir spot welding (FSSW) process. The determination of the welding parameters plays an important role for the weld strength. For the effective use of the dissimilar aluminum joints, the FSSW must have an adequate strength. The quality of the joint was evaluated by examining the characteristics of the joining efficiency as a result of the lap-shear tensile test. Four process parameters were selected: the tool rotation speed, dwell time, tool plunge depth, and tilt angle.The process parameters were optimized by Taguchi technique based on Taguchi’s L9 orthogonal array. The optimum welding process parameters were predicted, and their percentage of contribution was estimated by applying the signal-to-noise ratio and analysis of variance. The experimental results showed that the positioning of the plates played an important role on the strength of the joints. Finally, the results were confirmed by further experiments.     

A proximate-time-optimal-control design and its application to a hard disk drive dual-stage actuator system

We propose a compensator-based strategy for design of a track-seeking and track-following control system for a dual-stage servo actuator in hard disk drives. A well-known decoupling structure is employed to disconnect the control of the primary voice coil motor (VCM) actuator from the loop for a secondary high-bandwidth actuator. The compensator is placed in the secondary loop and suitably combined with a saturation nonlinearity in order to obtain actuator signal boundedness. The design procedure consists of four steps: 1) design of an established nonlinear seek-settle-track following controller for the VCM; 2) design of a linear track following controller for the secondary actuator; 3) observer design; and 4) design of a compensator to retain global stability and to improve performance. The proposed control system improves performance of both long-span seeking (proximate-time-optimal controller) and short-span seeking. In addition, it achieves high-bandwidth track following performance. The experimental results show good track-following performance, and short-span/long-span-seeking performance with fast settling time. The overshoot during track seeking can be made negligible for a suitably tuned VCM-actuator control loop.     

Turbidity removal of fine coal–water suspension by flocculation using Taguchi (L16) experimental design

Taguchi method is rather practical way for setting the best combination of different variables for various parameters in such phenomenon requiring excessive number of experiments. In this study, a series of flocculation experiments were performed using Taguchi (L₁₆) experimental design to determine the optimum conditions for the turbidity removal from fine coal suspensions. The effects of some controllable factors on the turbidity removal were evaluated by effective flocculation recovery via analysis of mean statistical approach and the percentage contributions of each parameters were also defined using analysis of variance statistical approach. The most influential factor was determined as the polymer concentration with a contribution of 47.831%. The optimum conditions were ascertained as pH?=?7, stirring speed of 500?rpm, polymer concentration of 2?mg/L, flocculation time of 3?min, and polymer type of 934SH.     

Optimization of process parameters of friction welding of UNS S31803 duplex stainless steels joints

This article presents an approach based on Taguchi method and Grey relational analysis to optimize process parameters of friction welding of UNS31803 duplex stainless steel. The main objective is to maximize mechanical properties like tensile strength, hardness and impact toughness and to minimize corrosion rate. Heating pressure, heating time, upsetting pressure and upsetting time were the four process parameters taken each at three levels. According to Taguchi quality design concept, an L9 orthogonal array was selected for experiments. The best combination of process parameters was found by both Taguchi method and Grey relational analysis. The influence of the process parameters on overall quality characteristics of the friction welding process was evaluated by the analysis of variance (ANOVA) method. The confirmation test results with optimal parameters confirmed the effectiveness of the proposed method in this study. Later, comparison was done between Taguchi method and Grey relational analysis on the basis of improvement in multiresponse signal to noise (S/N) ratio over initial process parameters. Grey relational analysis was proved to be a better technique than Taguchi method for optimization of multiple responses.     

Optimization of microstructural and mechanical properties of friction stir welding using the cellular automaton and Taguchi method

In this study, microstructural and mechanical properties of friction stir welding (FSW) of AA1100 is optimized using Taguchi L9 orthogonal design of experiments. First, in order to study the microstructural properties of the weld, microstructure evolution of the weld zone is simulated with the cellular automaton (CA) method coupling the modified Laasraoui–Jonas (LJ) model. Then, the microstructural simulation results were validated by obtained experimental results. Good agreements between the simulation and the experimental results were observed. Then, tensile and hardness test were done to investigate the mechanical properties of the weld. The design parameters considered in the experiment were rotational speed, traverse speed, and shoulder diameter. The optimum process parameters were determined with reference to grain size (GS), ultimate tensile strength (UTS) and hardness. The predicted optimal value of grain size, ultimate tensile strength and hardness was validated by conducting the confirmation test using optimum parameters. Analysis of variance was done in order to determine the most dominant factors in friction stir welding.     

Robust design optimisation via surrogate network model and soft outer array design

Robust design searches for a performance optimum with least sensitivity to variable and parameter variations. Taguchi method applies an inner array for control factors and an outer array for noise factors to estimate the Signal-to-Noise ratio (S/N). However, the cross product arrays impose serious cost concerns for expensive samplings. Also, rigorous control of noise factors to pre-set levels is impractical in industrial applications. This study presents a soft computing-based robust optimisation that merges control and noise factors into a combined experimental design to establish a surrogate using artificial neural network. Genetic algorithm is applied to search in the sub-space of control factors in the surrogate with a soft outer array to estimate the S/N served as the evolution fitness. Performance variations due to the tolerances of control and uncontrollable factors can then be estimated without conducting actual experiments. The verifications of the predicted optima become additional learning samples to refine the surrogate, and the iteration continues until convergence. The robust optimisation of a micro-accelerometer with maximised gain is used as an illustrative example. The proposed algorithm provides a superior robust optimum using a much smaller sample and less controlling cost compared with Taguchi method and a conventional response surface method.     

Compressive strength of ash-based geopolymers at early ages designed by Taguchi method

In the present work, compressive strength of ash-based geopolymers has been designed by Taguchi method at 2 and 7 days of water curing. Three factors including oven curing temperature (at 3 levels of 25, 70, and 90 °C), oven curing time (at 3 levels of 2, 4, and 8 h) and sodium hydroxide (NaOH) concentration (at 3 levels of 5, 8, and 12 M) were considered. By utilizing L9 Taguchi array, 9 series of experiments were conducted on the prepared specimens. The aluminosilicate source was a mixture of fly ash and rice husk ash while the alkali activating was done by a mixture of NaOH and sodium silicate solution. The obtained results were evaluated by analysis of variance (ANOVA) method to determine the optimum level of each factor. In all produced specimens, the optimum level of oven curing temperature was always 90 °C to achieve the highest compressive strength. Furthermore, the optimum strength was obtained by applying light and middle concentration of NaOH in approximately all specimens. Finally, the oven curing time was not an important factor to determine the compressive strength. To validate the accuracy of the optimum conditions suggested by ANOVA, compressive specimens were made and tested in accordance to the optimum conditions for each of 2 and 7 days water curing regimes. The compressive strength acquired from this situation was higher than those of proposed in initial 9 series of experiments for each of 2 and 7 days water curing regimes.     

An investigation on the optimum conditions of synthesizing a magnetite based ferrofluid as MRI contrast agent using Taguchi method

In this study, some stabilized magnetite based ferrofluids were synthesized using Dextran as a stabilizing agent. In order to achieve optimum experimental conditions for synthesizing ferrofluids as MRI contrast agents, the Taguchi method was used. This approach was employed to design and minimize the number of required experiments. By using the Taguchi orthogonal (L16) array, four parameters including solution temperature and alkalinity, reaction temperature and stirring rate were selected at four predetermined levels for 16 experiments. Synthesizing processes established based on this set of experimental conditions were carried out and the obtained ferrofluids were characterized using PCS, VSM, TEM and FT-IR techniques. The obtained results were used and analyzed through the Qualitek-4 software and the proposed optimum experimental conditions were used for synthesizing the desired sample. Finally, this sample was used as a potential MRI contrast agent for imaging lymph nodes.     

Color removal from textile dyebath effluents in a zeolite fixed bed reactor: determination of optimum process conditions using Taguchi method

Taguchi method was applied as an experimental design to determine optimum conditions for color removal from textile dyebath house effluents in a zeolite fixed bed reactor. After the parameters were determined to treat real textile wastewater, adsorption experiments were carried out. The breakthrough curves for adsorption studies were constructed under different conditions by plotting the normalized effluent color intensity (C/C(0)) versus time (min) or bed volumes (BV). The chosen experimental parameters and their ranges are: HTAB concentration (C(htab)), 1-7.5 gL(-1); HTAB feeding flowrate (Q(htab)), 0.015-0.075 L min(-1); textile wastewater flowrate (Q(dye)), 0.025-0.050 L min(-1) and zeolite bed height (H(bed)), 25-50 cm, respectively. Mixed orthogonal array L(16) (4(2)x2(2)) for experimental plan and the larger the better response category were selected to determine the optimum conditions. The optimum conditions were found to be as follows: HTAB concentration (C(htab))=1g L(-1), HTAB feeding flowrate (Q(htab))=0.015 L min(-1), textile wastewater flowrate (Q(dye))=0.025 L min(-1) and bed height (H(bed))=50 cm. Under these conditions, the treated wastewater volume reached a maximum while the bed volumes (BV) were about 217. While HTAB concentration, gL(-1) (A); zeolite bed height, cm (D) and wastewater flowrate, L min(-1) (C) were found to be significant parameters, respectively, whereas, HTAB flowrate, L min(-1) (B) was found to be an insignificant parameter.     

Taguchi design-based optimization of sandwich immunoassay microarrays for detecting breast cancer biomarkers

Taguchi design, a statistics-based design of experiment method, is widely used for optimization of products and complex production processes in many different industries. However, its use for antibody microarray optimization has remained underappreciated. Here, we provide a brief explanation of Taguchi design and present its use for the optimization of antibody sandwich immunoassay microarray with five breast cancer biomarkers: CA15-3, CEA, HER2, MMP9, and uPA. Two successive optimization rounds with each 16 experimental trials were performed. We tested three factors (capture antibody, detection antibody, and analyte) at four different levels (concentrations) in the first round and seven factors (including buffer solution, streptavidin-Cy5 dye conjugate concentration, and incubation times for five assay steps) with two levels each in the second round; five two-factor interactions between selected pairs of factors were also tested. The optimal levels for each factor as measured by net assay signal increase were determined graphically, and the significance of each factor was analyzed statistically. The concentration of capture antibody, streptavidin-Cy5, and buffer composition were identified as the most significant factors for all assays; analyte incubation time and detection antibody concentration were significant only for MMP9 and CA15-3, respectively. Interactions between pairs of factors were identified, but were less influential compared with single factor effects. After Taguchi optimization, the assay sensitivity was improved between 7 and 68 times, depending on the analyte, reaching 640 fg/mL for uPA, and the maximal signal intensity increased between 1.8 and 3 times. These results suggest that Taguchi design is an efficient and useful approach for the rapid optimization of antibody microarrays.     

The optimum conditions for comminution of magnetic particles driven by a rotating magnetic field using the Taguchi method

Using the Taguchi method, this study analyzed the optimum conditions for comminution of magnetic particles (such as Ni particles) in pure water contained in a flask, which was located on top of an actuator that contained a rotating bar magnet. The controllable factors used in this study consisted of the following: (1) the container, (2) the mass ratio of water-to-Ni particles, (3) the rotation speed of the bar magnet and (4) the time of attrition. The percentage contribution of each controllable factor was also determined. A digital camera and a particle-size analyzer were used to record the flow patterns and particle-size distributions of Ni, respectively. The confirmation experiment was carried out according to the optimum conditions, so that the average percentage of the optimum particle size (?100 nm) and the smallest particle sizes could reach 80.59% and 22.5 nm, respectively.     

共焦双光头多层数据存储系统

为了实现双光子多层数据存储系统的实用化,利用现有DVD高精度聚焦、循迹伺服技术,构建了共焦双光头多层数据读写系统,实现读写焦点在三维存储材料中的精确定位.同时由D/A输出选层信号控制音圈电机,实现了层间跳转,达到了多层读写之目的.本文通过建立光学头的音圈电机模型以及音圈电机控制器模型,实现对共焦双光头多层存储系统的建模与仿真,并给出已有的实验结果.     

Characteristic Analysis of EDMed Surfaces Using the Taguchi Approach

The electro-discharge machining (EDM) process plays an important role in manufacturing tools and dies. However, the performance and service life of an EDMed workpiece is greatly influenced by the surface characteristics developed during surface erosion. In this research, the Taguchi method was employed to evaluate the main factors influencing the characteristics of EDMed surface. With an aim to minimizing the formation of defects and obtaining optimum working conditions of EDM.

Analyzed results show that the main influencing factors for hole-enlargement are pulse current, pulse-on duration, and gap voltage. The main influencing factors for surface roughness are the pulse current, pulse-on duration, and specimen materials, while gap voltage is found to have only a negligible effect. Pulse current and pulse-on duration are the most important influencing factors affecting the thickness of the white layer. Estimations and confirmation experiments were performed, verifying the Taguchi predictions.     

Application of a response surface method to the optimal design of the wall temperature profiles in extrusion die

A new approach to the optimal design of the die wall temperature profile in polymer extrusion processes is presented. In this approach, optimization of the design variables is conducted by a Response Surface Method (RSM) and the Sequential Quadratic Programming (SQP) algorithm. Design of experiment (DoE) needed for the construction of the response surface is used to evaluate the objective and the constraint functions on the basis of a finite element method (FEM). Two designs of experiments are used and the performances of the optimization results are compared with respect to efficiency and ability to obtain a global optimum. Typically, for extrusion die design, the objective function states that the average velocity across the die exit is uniform. Constraints are used to limit the pressure drop in the die. For this purpose, we optimize the wall temperature profile of a coat hanger die in a heterogeneous way, (i.e. the wall temperature may not be constant in the entire die). The melt temperature enables us to locally control the viscosity, which influences the flows in the various zones. The effect of the design variables in the objective and constraint functions is investigated using Taguchi method. The flow analysis results are then combined with an automatic optimization algorithm to provide a new profile of the die wall temperature distributions.     

The use of a grey-based Taguchi method for optimizing multi-response simulation problems

Simulation modelling is a widely accepted tool in system design and analysis, particularly when the system or environment has stochastic and nonlinear behaviour. However, it does not provide a method for optimization. In general, problems contain more than one response, which are often in conflict with each other. This article proposes a grey-based Taguchi method to solve the multi-response simulation problem. The grey-based Taguchi method is based on the optimizing procedure of the Taguchi method, and adopts grey relational analysis (GRA) to transfer multi-response problems into single-response problems. A practical case study from an integrated-circuit packaging company illustrates that differences in performance of the proposed grey-based Taguchi method and other methods found in the literature were not significant. The grey-based Taguchi method thus provides a new option when solving a multi-response simulation-optimization problem.     

Laser parameter optimization for surface texturing of inconel 625

The optimum laser parameters required for the inconel 625 alloy surfaces to have the desired properties have been determined. Process parameters were optimized to get maximum heat affected zone depth (HAZ) and width and maximum aspect ratio and minimum defect outside of the spot area independently of each other. Also, the effect rates of the examined process parameters on the treated surface quality were determined separately for each surface feature. As a result of optimization using Taguchi method, the most effective parameters to obtain the desired surface were obtained as gas type with 72.26 % for heat affected zone depth, gas type with 90.46 % for heat affected zone width, gas type with 81.57 % for aspect ratio, pulse energy with 30.99 % for minimum defect outside of the spot area. The best results were obtained on the surfaces obtained as a result of the confirmation experiment with the new parameters obtained with the Taguchi method. Since the results of the confirmation experiments are highly compatible with the results suggested by the Taguchi method, the Taguchi method may be concluded as reliable in the laser ablation of the inconel 625 surface.     

Optimization of counter flow Ranque–Hilsch vortex tube performance using Taguchi method

This study discusses the application of Taguchi method in assessing maximum temperature gradient for the Ranque–Hilsch counter flow vortex tube performance. The experiments were planned based on Taguchi's L27 orthogonal array with each trial performed under different conditions of inlet pressure, nozzle number and fluid type. Signal-to-noise ratio (S/N) analysis, analysis of variance (ANOVA) and regression analysis were carried out in order to determine the effects of process parameters and optimal factor settings. Finally, confirmation tests verified that Taguchi method achieved optimization of counter flow Ranque–Hilsch vortex tube performance with sufficient accuracy.     

Optimization in CNC end milling of UNS C34000 medimum leaded brass with multiple surface roughnesses characteristics

The present study highlights a multi-objective optimization problem by applying utility concept coupled with Taguchi method through a case study in CNC end milling of UNS C34000 medium leaded brass. The study aimed at evaluating the best process environment which could simultaneously satisfy multiple requirements of surface quality. In view of the fact, the traditional Taguchi method cannot solve a multi-objective optimization problem; to overcome this limitation, utility theory has been coupled with Taguchi method. Depending on Taguchi’s Lower-the-Better (LB) response criteria; individual surface quality characteristics has been transformed into corresponding utility values. Individual utility values have been aggregated finally to compute overall utility degree which serves as representative objective function for optimizing using Taguchi method. Utility theory has been adopted to convert a multi-response optimization problem into a single response optimization problem; in which overall utility degree serves as the representative single objective function for optimization. The study of combined utility theory and Taguchi method for predicting optimal setting. Based on Taguchi’s Signal-to-Noise ratio (S/N), analysis has been made on the overall utility degree and optimal process environment has been selected finally which corresponds to highest S/N Ratio. Optimal result has been verified through confirmatory test. The case study indicates application feasibility of the aforesaid methodology proposed for multiresponse optimization and off-line control of multiple surface quality characteristics in CNC end milling.     

A Precision-Positioning Method for a High-Acceleration Low-Load Mechanism Based on Optimal Spatial and Temporal Distribution of Inertial Energy

High-speed and precision positioning are fund a mental requirements for high-acceleration low-load mechanisms in integrated circuit(IC) packaging equipment. In this paper, we derive the transient nonlinear dynamicresponse equations of high-acceleration mechanisms, which reveal that stiff ness, frequency, damping, and driving frequency are the primary factors. Therefore, we propose a new structural optimization and velocity-planning method for the precision positioning of a high-acceleration mechanism based on optimal spatial and temporal distribution of inertial energy. For structural optimization, we first reviewed the commonly flexible multibody dynamic optimization using equivalent static loads method(ESLM), and then we selected the modifled ESLM for optimal spatial distribution of inertial energy; hence, not only the stiff ness but also the inertia and frequency of the real modal shapes are considered. For velocity planning, we developed a new velocity-planning method based on nonlinear dynamic-response optimization with varying motion conditions. Our method was verifled on a high-acceleration die bonder. The amplitude of residual vibration could be decreased by more than 20% via structural optimization and the positioning time could be reduced by more than 40% via asymmetric variable veloci ty planning. This method provides an effective theoretical support for the precision positioning of high-acceleration low-load mechanisms.