Integrating Taguchi Method and Gray Relational Analysis for Auto Locks by Using Multiobjective Design in Computer-Aided Engineering

Huang, Weng Foung; Tasi, ZiYun; Ho, Wen-Hsien; Chou, Jyh–Horng

doi:10.3390/polym14030644

Cited by 17 publications

(6 citation statements)

References 24 publications

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“…The Taguchi method was applied to identify the optimal process design for achieving the ideal functional target characteristic [ 35 ], with the aim of stabilizing the error value within 3.4 ± 0.1 g. Considering key performance indicators (KPIs) and operational cost profitability [ 36 ], the predicted quality control setting assumed that the weight of PP-C90 cup lids could be stably controlled within ± the specified error. Approaching 3.3 g was deemed the optimal process design without adopting the “smaller-the-better” characteristic [ 37 ] as the research design goal. This method was applied to avoid potential quality instability and customer complaints caused by excessively light product weight.…”

Section: Research Methods and Analysis Experimentsmentioning

confidence: 99%

“…The experimental design selected an orthogonal array [23] based on eight control factors. Among these, 1 factor has two levels (21), and 7 factors have three levels each (37), forming a predominantly "mixed level" "design. The chosen experimental quality characteristic orthogonal array is denoted as L 18 (2 1 × 3 7 ), as illustrated in Table 4.…”

Section: Analysis Of Variance (Anova)mentioning

confidence: 99%

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Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Chen,

Huang

2024

Polymers

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This research investigates the control of thickness and weight in plastic extrusion vacuum-thermoforming products to identify optimal key parameters for cost reduction and energy savings. The initial step involves identifying crucial influencing factors. In this step, the Delphi technique was employed through a questionnaire administered to a panel of expert scholars to ensure minimal error and maximal reliability in determining key influencing factors. Consensus was sought to establish appropriateness and consistency. Subsequently, the Taguchi method was applied for quality design and planning of the extrusion vacuum-forming process. The experimental design parameters were selected using an L18 (21 × 37) orthogonal array, and the desired quality characteristics were determined. Comparative analysis of quantitative production data from two consecutive experiments was conducted, and based on F-values and contribution analysis, the combination of control factors maximizing the Signal-to-Noise (S/N) ratio was identified. The objective is to seek optimal parameters for improving the quality of the plastic polypropylene (PP cup lid) manufacturing process, reducing process variability, and identifying the most robust production conditions. Through multiple actual production prediction experiments, it was determined that five control factors, “polypropylene new material ratio,” “T-die lips adjustment thickness”, “mirror wheel temperature stability”, “molding vacuum pressure time”, and “forming mold area design”, contribute to the maximization of the S/N ratio, i.e., minimizing variability. Statistical validation confirms a significant improvement in product quality and weight control. Noteworthily, the quality control model and experimental design parameters established in this study are also applicable to other plastic products and bio-based materials, such as PET, HIPS, and biodegradable PLA lids with added calcium carbonate. The results of the experimental production demonstrate its ability to consistently control product weight within the range of 3.4 ± 0.1 g, approaching the specified tolerance limits. This capability results in approximately 2.6% cost savings in product weight, contributing significantly to achieving a company’s KPI goals for environmental conservation, energy efficiency, and operational cost reduction. Therefore, the findings of this study represent a substantial and tangible contribution.

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Section: Research Methods and Analysis Experimentsmentioning

confidence: 99%

Section: Analysis Of Variance (Anova)mentioning

confidence: 99%

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Chen,

Huang

2024

Polymers

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“…The robust design for the multi-objective problems is found in the Pareto frontier of solutions. Many authors [35][36][37][38] have integrated only the S/N ratio approach and grey relation analysis to optimize multi-objective quality characteristics. Parinam et al [39] presented a design parameter optimization procedure, which combines the Taguchi technique with a genetic algorithm to obtain the optimal values of the design parameters.…”

Section: Robust Design Of Products and Processesmentioning

confidence: 99%

Static Robust Design Optimization Using the Stochastic Frontier Method: A Case Study of Pulsed EPD Process on TiO2 Films

Rezgui,

Trabelsi,

Barbana

et al. 2024

Inventions

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This paper aims to optimize a pulsed electrophoretic deposition (EPD) process for TiO2 films. This is accomplished by determining the optimal configuration of the coating parameters from a robust optimization perspective. The experimental study uses a composite central design (CCD) with four control factors, i.e., the initial concentration (x1 in g/L), the deposition time (x2 in s), the duty cycle (x3 in %), and the voltage (x4 in V). The process responses that should all be maximized are the photocatalytic efficiency of the thin film (De) and three critical charges, which characterize the adhesion failure, i.e., LC1: the load at which the first cracks occurred; LC2: the load at which the film starts to delaminate at the edge level of the scratch track; and LC3: the load when the damage of the film exceeds 50%. This paper compares the robust optimization design of the EPD process using two methods: the robust design of processes and products using the stochastic frontier (RDPP-SF) and the surface response and desirability function methods. The findings show that the RDPP-SF method is superior to the response surface–desirability method for the process responses De and LC2 because of non-natural sources of variation; however, both methods perform comparably well while analyzing the LC1 and LC3 responses, which are subjected to pure random variability. The parameters setting for the process robust optimization are met in run 25 (x1 = 14 g/L, x2 = 150 s, x3 = 50%, and x4 40 V).

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“…In the same way, a uniform distribution of temperatures on the surface of the part helps to not only reduce the cooling time, but also helps to improve the quality of the part in terms of metrology [ 23 ]. An unbalanced temperature map can cause warpage in the plastic part and result in the rejection of manufactured parts, which goes against the industrial sustainability criteria currently required [ 24 ].…”

Section: Introductionmentioning

confidence: 99%

Application of New Conformal Cooling Layouts to the Green Injection Molding of Complex Slender Polymeric Parts with High Dimensional Specifications

et al. 2023

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Eliminating warpage in injection molded polymeric parts is one of the most important problems in the injection molding industry today. This situation is critical in geometries that are particularly susceptible to warping due to their geometric features, and this occurs with topologies of great length and slenderness with high changes in thickness. These features are, in these special geometries, impossible to manufacture with traditional technologies to meet the dimensional and sustainable requirements of the industry. This paper presents an innovative green conformal cooling system that is specifically designed for parts with slender geometric shapes that are highly susceptible to warping. Additionally, the work presented by the authors investigates the importance of using highly conductive inserts made of steel alloys in combination with the use of additively manufactured conformal channels for reducing influential parameters, such as warpage, cooling time, and residual stresses in the complex manufacturing of long and slender parts. The results of this real industrial case study indicated that the use of conformal cooling layouts decreased the cycle time by 175.1 s—66% below the current cooling time; the temperature gradient by 78.5%—specifically, 18.16 ºC; the residual stress by 39.78 MPa—or 81.88 %; and the warpage by 6.9 mm—or 90.5%. In this way, it was possible to achieve a final warping in the complex geometry studied of 0.72 mm, which was under the maximum value required at the industrial level of 1 mm. The resulting values obtained by the researchers present a turning point from which the manufacturing and sustainability in the injection molding of said plastic geometries is possible, and they take into account that the geometric manufacturing features analyzed will present a great demand in the coming years in the auto parts manufacturing industry.

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Integrating Taguchi Method and Gray Relational Analysis for Auto Locks by Using Multiobjective Design in Computer-Aided Engineering

Cited by 17 publications

References 24 publications

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Static Robust Design Optimization Using the Stochastic Frontier Method: A Case Study of Pulsed EPD Process on TiO2 Films

Application of New Conformal Cooling Layouts to the Green Injection Molding of Complex Slender Polymeric Parts with High Dimensional Specifications

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