ISSN 2230- 9373
Volume-IX , Issue-1
January-March, 2019
Application of Taguchi Method for Process Optimization on Different
Fields of Engineering- A review
Shakti Prakash Jena , Sankalp Mahapatra
Department of Mechanical Engineering, ITER, SOA deemed to be University, Bhubaneswar E-mail: [email protected]
ABSTRACT
In this globalization era the major competition between the industries is related to the two main aspects i.e. quality and productivity. Productivity concentrates towards the profitability aspects of the company which include increment in production rate with reducing cost as well as time aspects. The current study attempts to present an intensive literature survey on use of Taguchi method in different fields of engineering with a specific emphasis on the impact of different operational parameters on multiple performance measures, which can lead to achieve the optimal parametric combinations that can improve the process to get optimized output. These reviews demonstrated that this optimisation method was efficient and can greatly reduce the operational cost and the design process.
INTRODUCTION
Nowadays it is difficult to counter the growing demand of different products in different field. As the population is increasing the demand of goods and services are also necessary and increases in proportional manner. Increasing man power is just not enough to counter these problems because, for producing a large quantity of goods with minimum defect there is the foremost requirement of optimization of process parameters. For this motive Genichi Taguchi developed a method for increasing the quality of goods induced in his farm which was later known as the Taguchi methods or Taguchi Technique. This method is not only restricted to the field of forming, nowadays it is widely used in various fields like engineering, marketing, biotechnology, advertising, production.
Taguchi addresses quality into two main areas offline and online quality. Both of these areas are very cost sensitive. Offline quality control deals with the improvement in quality of the product and process development stages. Online quality control deals with the monitoring of current manufacturing process to verify the quality levels produced. Taguchi method bared designs are different from the classical experiments designs by Taguchi method minimizes the variance of characteristics of interests. But the major limitation it has is it is only effective in solving single response problems.
The Taguchi method optimizes a process or product design in three main stages.
Parameter design Tolerance design
The concept design is called as the first step of a design strategy. This stage gathers the technical knowledge and experiences to help the designer to select the most suitable design for a given product. Then comes the parameter design. Here the best setting of the control factors is determined. This is the most important step as it does not affect the manufacturing cost of each single unit of product. After these two steps are done the third step which is called the tolerance design is initiated. This process deals with the relation between quality and cost. Here the designers only consider upgrading material standards and components if any [1].
LITERATURE SURVEY
Many researchers and scientists have debated on the use of Taguchi method in different fields. As it reduces the number of experiments performed in getting the optimum combination of entities it is widely preferred and appreciated because it saves time and money without compromising with the quality of a product. Here are some of the experiments done previously by different scholars in their respective fields.
Zhang -yi HU et al [2] studied the combustion characteristic and optimal factors determination in diesel / biodiesel engine with port injecting liquid petroleum gas (LPG). They experimented on the optimal operating factors of the largest fuel consumption time, the lowest smoke and oxides of nitrogen with taguchi methods are verified to be 90% Success. The best combination of blend thus obtained is 40% LPG, 20% exhaust gas recirculation ratio (EGR). This combination improves combustion characteristics and the combination obtained does not have any harmful effects on the engine.
R. Sathish Kumar et al. [3] investigated production of biodiesel from Manilkara Zapota seed oil using Taguchi method. They optimize the critical process parameters influencing the transesterification process but a new biodiesel developed from M. Zapota seed by using Methanol and KOH as catalyst. They found that the optimum conditions for the production of Manilkara Zapota Methyl ester (MZME) are 6:1 methanol to oil molar ratio at 1% concentration of the catalyst. The reaction time is approximately 90 minutes.
T. Ganapathy et al. [4] studied the optimization of performance of Jatropha biodiesel engine model using Taguchi method. They optimize various input parameters of the engine using signal to noise ratio (SNR). They used a C16 orthogonal array to carry out the experiments. They found out that compression ratio was the most important parameter and the other parameters include diffusive zone heat release constant, diffusive zone combustion duration etc. The Taguchi’s approach based thermodynamic model has slightly improved the performance parameters.
Holga Karabas [5] has experimented on the production of biodiesel from crude acorn Kernel oil using Taguchi’s optimization technique. He investigated the optimization and effects of process parameters on the production of acorn kernel oil methyl ester with the help of analysis of variants (ANOVA). He found out that reaction time has the strongest influence in the production process and it is twice as important of the second most important factor that is alcohol oil molar ratio and his tests indicated that the yield of acorn kernel oil methyl ester significantly increases using Taguchi’s technique.
K.Shivaramakrishnanan and P Ravi Kumar [7] has studied the optimisation of performance by a Karanja biodiesel engine using taguchi method. They optimise the input parameters using SNR. They found out that diesel engine operating at high compression ratio 17:9, high pressure 230 bar injection timing of 27 degrees and biodiesel/diesel blend (B30) and brake power of 3.64 kW achieves the optimum engine performance Based on their study they conclude that karanja oil methyl ester can be regarded as a substitute to diesel fuel.
Nandakishore et al. [8] studied the engine characteristic optimisation using neem oil-ethanol blend they have used the taguchi method along with the grey rational analysis for the optimisation of a diesel engine. The compression ratio was found out to be the most important factor. based on their study they conclude that Brake Thermal Efficiency, Brake Specific Energy Consumption and emission of diesel engine depends upon compression ratio injector operating pressure and fuel injection technique they found out that Cr-18, FIT-27degree achieves optimum engine performance.
Gorkem Kokkulunk et al. [9] studied the optimisation of factors effecting engine performance and emission of exhaust gas recirculation in steam injected diesel engine. They optimised the factors like engine speed steam and EGR ratios. They found out that the optimum conditions are steam ratio is 10% for oxides of nitrogen and 20% for specific fuel consumption (SFC). And the minimum fuel consumption is found out with 0% EGR ratio.
Goteti and Reddy [10] experimented on the design of the internal combustions engine rocker arm using taguchi method. they found out that the optimal combination for maximum fatigue life is for rocker made of arm ratio 1:1 with structural steel and the total deformation is minimum in the case of material Al6061 with arm ratio 1:1.3.
Gautam and Kumar [11] studied the optimisation of IC engine piston using taguchi methods. They have used an orthogonal array L16 made of five factors and 4 levels of piston design. The main conclusion they have drawn from their study was as per SNR ratio the most important factor is crown temperature of piston and least important factor is thermal coating material applied to piston head and side walls. The optimal thermal stress was found to be 347 MPa.
Valli and Jindal [12] studied the effects of physical parameters affecting the performance of pulse detonation engine. The level of importance of physical parameters on thrust were determined by using taguchis L50 orthogonal array method and ANOVA. They have found out that it is possible to increase the thrust significantly by using the proposed technique by taguchi.
K Prasad Rao et al. [13] studied the performance parameter optimisation of a biofuel fuelled diesel engine they have used the performance parameters such as 10CC fuel consumption, load type of fuel and valve opening position. They found out that load is the most significant factor and the whole optimisation will get affected if there will be a change in load.
Mustafa Kemal Balki [14] studied the optimisation of operating parameters based on taguchi method in a SI engine using pure gasoline Ethanol and Methanol. They searched the optimum operating under three different compression ratios, ignition timing and engine speeds with three different levels they found out that the result have a confidence interval of 95% and are compatible with confirmation experiments this shows that the taguchi method can be usable to define optimum working conditions in an IC engine saving a large duration of time.
Anil Gupta [16] et al. studied the Multi Output Optimisation (MOO) in high speed CNC turning of AISI P-20 tool steel using taguchi fuzzy method. They found out that the fuzzification process takes care of the vagueness in the information and produces the best suitable conditions for cutting. They found out that after optimizing the four performance parameters which are surface roughness, tool life, cutting force and power consumption the MOO can be increased.
Asilturk and Neseli [17] studied the multi response parameter of CNC turning by taguchi method-based surface analysis. They have found out the SNR for all done experiments along with the objective functions. After optimizing the performance parameters, they found out that it has increased the efficiency of the CNC turning and the machining cost was reduced significantly.
Jayaraman and Kumar [18] studied the multi response optimisation of machining process of turning of AA6063 T6 aluminium alloy using grey rational analysis in taguchi method. They measured the surface roughness, roundness and material removal rate under different cutting conditions for wide combinations of machining process. They found out that the feed rate is most important factor followed by depth of cut and cutting speed. The best results were obtained with lower cutting speed of 119.2 m/min lower feed rate of 0.05 min/revolution and medium depth cut of 0.15mm with estimated multiple performance characteristic of 0.8084.
Horng Weng Wu and Zhan Yi Wu [19] studied the use of taguchi method on optimising the combustion performance of a diesel engine with diesel biodiesel blend and port introducing hydrogen gas. They have given importance to BTE, BSFC, oxides of nitrogen and smoke in their study. They found out that the best results are achieved from combination of 30% of hydrogen 40% of EGR ratio which improves the combustion performance and saves 67% of time taken to perform experiments.
Adnan Parlak et al. [20] studied applications of taguchi method to investigate factors affecting emission of a diesel engine running with tobacco seed methyl ester. They have investigated the conditions to maximize brake torque and conditions that minimises the brake specific fuel consumption (BSFC) and emissions. They found out that KOH is a better catalyst for brake toque whereas NaOH is a better catalyst for BSFC and emissions. Also, oxygen content should be minimized as it would decrease the performance and blend rate plays an important role in their study as increase in blend would decrease the harmful emissions.
S. Natarajan et al. [21] experimented on effect of injection timing on CI engines fuelled with algae oil blend with taguchi method. They concluded that with the advanced injection timing of 27-degree BTDC brake thermal efficiency was increased by 5.70 % and CO emissions were reduced up to 81.25% whereas oxide of nitrogen were reduced by 27.98% With a retardation in injection timing of 19-degree b TDC. Also, unburnt hydrocarbons and smoke emissions were reduced by 30% and 26.93% each.
Lee et al. [22] experimented on the development of a highly efficient low emission diesel engine powered co-generation system. A minimum number of experiments were done by using the methods of ANOVA and taguchi technique. They found out that efficiency of the co-generation system attains a maximum 85.7% at a water flow rate of 20 LPM and an electric power output of 25 KW with a ceramic heater input of 4 KW. The resulted efficiency is 6% higher than that of typical co-generation system.
Khidir and Atrooshi [23] investigated the performance parameters and exergy of a diesel engine using four type of diesel fuel. They found out that throttle position has no effect on the volumetric efficiency. The optimum temperature for improved BTE is 80˚C. The optimum engine speed for the test engine based on maximum volumetric efficiency and minimum BSFC also improved values of thermal and exergy efficiencies was found out to be 2500 rpm.
N=S are appropriate considering the high performance and reasonable pressure drop. They optimised the operating parameter affecting the performance of PEMFC with rectangular cylinder installed at the axis transversely in the flow channel. They experimented on the optimal operating factors of the largest fuel consumption time, the lowest smoke, oxides of nitrogen (NOx) with Taguchi method. The
predictors of Taguchi method are verified to be 90% success. The best combination of blend thus obtained is 40% CPG and 20% exhaust gas recirculation ratio (EGR). This combination improves combustion characteristics and the combination obtained does not have any harmful effect on the engine.
CONCLUSIONS
The main objective of the present study was to offer background information on the aspects to be considered in this research and to highlight the significance of Taguchi method for optimization of process parameters in different areas of engineering applications.
In field of manufacturing different researchers have employed Taguchi method to optimization of machining parameters like cutting speed, feed rate, depth of cut, tool nose radius and cutting environment with respect to multiple performance measures like surface roughness, tool life, cutting force and power consumption.
Researchers also used Taguchi method to optimize the transesterification process parameters like reaction time, reaction temperature, concentration of catalysts etc. to achieve better rate of biodiesel production.
Taguchi method also used in the field of performance analysis of internal combustion engines to study the effect of control parameters like advancing of injection timing, fuel injection pressure, excess air ratio, blend ratio of alternative fuels, rate of inducted fuels etc. to locate the optimal combination of operating parameters to maintain best performance of the engine with alternative fuels.
Hence Taguchi method can be considered as a suitable tool to achieve the optimal parametric combinations that can improve the process to get optimized output in all sectors of engineering applications.
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