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Energy efficiency evaluation of metal laser direct deposition based on process characteristics and empirical modeling
摘要： Metal laser direct deposition (MLDD) is a typical process in additive manufacturing (AM), which permits the build of complex and fully dense metallic parts by using laser to melt the metal powder layer by layer. However, the process is characterized by high energy consumption and low energy efficiency. This paper established an empirical model to characterize the relationship between process parameters and energy efficiency for MLDD based on the essence of thermodynamics physical energy conversion. Additionally, a recognition method of cross-sectional profile of the deposited layer was achieved by adding tungsten carbide (WC) powder, which greatly improved the measurement reliability. Taguchi experiment and regression identification method were applied, and the relative error of the model was less than 10%. The results show that laser power has significant influence on the process energy efficiency of MLDD. The energy efficiency of single-track multi-layer stacking (SMS) process and multi-track single-layer lapping (MSL) process increased by 5.7% and 50.3%, respectively, under the optimal process parameter condition. The proposed model can be used effectively for the energy efficiency evaluation and offer the potential for improving the sustainability of MLDD.
关键词： Energy efficiency,Metal laser direct deposition (MLDD),Cross-sectional profile,Taguchi experiment
更新于2025-11-28 14:24:20
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An Improved Optical Parameter Optimisation Approach Using Taguchi and Genetic algorithm for High Transmission Optical Filter Design
摘要： High transmission optical filters require specific filter characteristics and set of optimisation methods since precision in output performance plays a vital role in such applications. In this paper, an improved genetic algorithm approach to optimise high transmission optical filter is described. High transmission of around 99% in the wavelength region of 525-575 nm without any dips in between is the main performance requirement desired. The optimisation parameters are layer thickness, refractive index and number of layers and design wavelength is 550 nm in visible region. The method integrates the Taguchi method and genetic algorithm. First, Taguchi method is used to reduce the number of design experiments and find the minimum possible number of optimised set of values that represents the quality performance of the system. Then, genetic algorithm is applied to search the optimal design parameters. The performance is determined in terms of transmittance. Three levels for each optimisation parameter were considered. The total number of design experiments to be performed (in worst case) using genetic algorithm only with three optimisation variables and three levels is approximately 33=27 for obtaining the best design that matches the desired performance whereas Taguchi integrated genetic method helped in finding the best matching design with 9 design experiments. The best transmission performance was obtained for 24 layers, with thickness range 10-123.75 nm and high and low refractive index of 2.1 and 1.38. This method is a very robust approach that can be used for design parameter optimisation of optical filters for high transmission applications.
关键词： Optical filters,Genetic algorithm,Taguchi,Optimisation
更新于2025-09-23 15:23:52
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Experimental data on the degradation of caffeine by photo-electro-fenton using BDD electrodes at pilot plant
摘要： Emerging contaminants (EC) are an imminent risk due to potential toxicity to aquatic ecosystems and human beings. This type of contaminants is found in low concentrations and usually present incomplete or inefficient removal by conventional treatments, which entail its permanence and constant increase. Advanced Oxidation Processes (AOP) are an alternative for the elimination of dangerous and resistant substances in wastewater. So, this research evaluates the caffeine degradation in aqueous solution by AOP, such as: Fenton, Electro-Oxidation (EO) with boron doped diamond (BDD) electrodes, Electro-Fenton (EF) and Photo-Electro-Fenton (PEF). The influences of pH, concentration of the supporting electrolyte and specific electric charge were investigated using a Taguchi's factorial design, which allowed to identify the contribution of each variable in the process. The data obtained in this work can be useful for scaling process and cost analysis because it provide the information at pilot plant scale.
关键词： Chemical engineering,Taguchi design,BDD electrodes,Advanced oxidation process,Caffeine degradation
更新于2025-09-23 15:23:52
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[IEEE 2019 IEEE International Conference on Manipulation, Manufacturing and Measurement on the Nanoscale (3M-NANO) - Zhenjiang, China (2019.8.4-2019.8.8)] 2019 IEEE International Conference on Manipulation, Manufacturing and Measurement on the Nanoscale (3M-NANO) - Study on Anti-reflection Performance of Titanium Alloy Based on the Change of Repeat Times of Nanosecond Laser Processing
摘要： A new and accurate edge extension formula based on the Taguchi method is proposed to calculate the resonant frequency of electrically thin and thick rectangular patch antennas with an air gap (RPAAG) and rectangular patch antennas without an air gap. Based on 3205 antennas data random distribution in the electrical substrate thickness h/λd ranging from 0.001 to 0.2 and the dielectric constant ranging from 1.0 to 10.2, the edge extension formula is created with the Taguchi method. The resonant frequencies predicted using the proposed formula are in better agreement with simulated and measured results than those calculated with the existing formulas in other literatures, especially for electrically thick substrates. Furthermore, experimental results for the RPAAG are given, which shows that h/λd should be less than 0.13 in the design of a capacitively fed RPAAG.
关键词： Edge extension formula,resonant frequency,electrically thin and thick substrates,rectangular patch antenna with and without an air gap,Taguchi method
更新于2025-09-23 15:21:01
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Numerical studies of metal particle behaviors inside the selective laser melting (SLM) chamber through computational fluid dynamics (CFD)
摘要： The flow behavior of the shielding gas has been a key factor to improve the quality of products manufactured by the selective laser melting (SLM) technology as it is a major mechanism to remove the ejected metal particles away from the working plane. In this study, to obtain a proper flow field, computational fluid dynamics (CFD) with the application of the Taguchi method was employed to investigate the flow field across the working chamber, with the variations in the geometries of the blowing nozzle, the widths of the suction tunnel, the suction-to-plane distances, and the Reynolds numbers of the blowing flow. The simulation was first verified with experimental measurements. The ejecting motions of the metal powders were also taken into consideration to study the interactions between the shielding gas and the ejected particles. The results demonstrated that axis switching as well as the suction-to-plane distance are the important factors for improving the particle removal efficiency during the SLM operation.
关键词： Selective laser melting,Computational fluid dynamics,Particle removal efficiency,3-D printing,Axis switching,Taguchi method
更新于2025-09-23 15:21:01
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Taguchi Grey Relationalapproach Foroptimizing Process Parameters of Laser Peeningontitanium Alloy to Induce Enhanced Compressive Stress Based on Finite Element Simulation
摘要： Laser Shock Peening (LSP) turned out the most efficient surface engineering process for advanced materials to induce beneficial deep compressive residual stress which helps in improving mechanical, fatigue properties and surface damage resistance. But, analyzing the non-uniform distribution of residual stresses in the treated sample with XRD is much time taking and costly process. This problem can be resolved with LSP finite element numerical simulation model which is feasible with the realistic experimental process. The FE model allows the user to control the laser parameters in order to achieve the optimal level of all controllable parameters. The present study is intended to analyze and optimize the influence of laser processing parameters assists in inducing the residual compressive stress with minimal surface deformation.A Ti6Al4V material model with Johnson-Cook’s visco-elastic-plastic material behaviour law is prepared for LSP simulation. And Gaussian pressure profile is utilized for uniform loading of the targeted zone for the proposed model. Taguchi Grey Relational Analysis (TGRA) with L27 orthogonal array is applied to LSP simulation, and the results were analyzed with consideration of multiple response measures. It is noted that surface deformation is increased with the rise in a number of laser shots and pressure pulse duration. Maximum compressive residual stresses are falling for higher levels of laser spot diameter, Laser spot overlap and Laser Power density. The correlation is observed between FE simulation and published results. The optimal set of process parameters are obtained for improving the LSP on Ti alloys.
关键词： Grey Relational Analysis (GRA),Taguchi Technique,Laser Shock Peening (LSP),Finite Element Method (FEM),Residual Stresses
更新于2025-09-23 15:21:01
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Application of Taguchi methodology for optimization of process parameters in laser bending of Al sheet
摘要： Laser bending process has many advantages including high flexibility, production of intricate shapes, precise incremental adjustments etc. The use of Nd:YAG laser for bending thin sheet aluminium is done frequently for various operations.In this experiment laser process parameters were optimized using Taguchi method. The response parameter governing the laser beam in Aluminium sheet bending were evaluated by measuring of the bending angle. Four input parameters such as laser power, scan speed, pulse diameter and pulse duration were taken into consideration for optimization. Furthermore, 25 combinations of these laser parameters were set and Taguchi methodology is used. The optimum parameter settings are: laser power 2.8 J, pulse diameter 2.0 mm, pulse duration 0.5 ns and scan speed 60%. The optimal result was confirmed with a superior bending angle as 200.
关键词： Bending angle,S/N ratio,Taguchi method,Spring back effect
更新于2025-09-23 15:21:01
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[IEEE 2018 19th International Conference on Electronic Packaging Technology (ICEPT) - Shanghai (2018.8.8-2018.8.11)] 2018 19th International Conference on Electronic Packaging Technology (ICEPT) - Simulation research on wafer warpage and internal stress in the First Passivation process of eSiFO package
摘要： In the electronics packaging process, warpage and thermal stress are two important causes which lead to packaging failure. In this paper, ABAQUS is used to perform three-dimensional numerical simulation of eSiFo packaging products from the thermodynamic point of view. The effects of different structural parameters on wafer warpage and thermal stress in electronic packages are simulated. In the simulation part, single factor analysis, Taguchi orthogonal experiment design and finite element analysis are combined to obtain the optimized process parameters and perform simulation analysis. The result shows that the structural parameter that has the greatest influence on the von Mises stress value of the wafer is the window size. And the structural parameter that has the greatest influence on the wafer warpage is the Die thickness. The thickness of the adhesive layer and the thickness of the passivation layer have a relatively small effect on the von Mises stress and the warpage value of the wafer. Under the optimized process parameters, the maximum von Mises stress and the maximum warpage value are much smaller than the initial process.
关键词： Taguchi orthogonal experiment,optimization of process parameters,numerical simulation,Warpage,thermal stress
更新于2025-09-23 15:21:01
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Study on process and manufacturability of metal-bonded diamond grinding wheel fabricated by selective laser melting (SLM)
摘要： Selective laser melting (SLM) technology is used to fabricate metal-bonded grinding wheel based on mixed powders consisted of metal powders and diamond abrasives. Taguchi method is adopted to obtain the optimal SLM process parameters for grinding wheel considering laser power, scanning speed and layer thickness. Specimens are fabricated with different SLM process parameters for compression and three-point bending tests. Materials characterization and manufacturing limit test are performed on the specimens fabricated by the optimal SLM process. Results indicate that laser power of 250W, scanning speed of 2.5m/s and layer thickness of 20μm are determined as the optimal SLM process in terms of comprehensive mechanical property and formed surface quality. Moreover, diamond abrasives are firmly embedded into aluminium binder with good bonding condition for SLM-fabricated composite. Furthermore, manufacturability of SLM-fabricated composite is evaluated by manufacturing limits of several common structures. In summary, work in this study fully proves the feasibility of SLM-fabricated metal-bonded grinding wheel and provides a solid basis for the further investigation on the novel grinding wheel with customized porous structures.
关键词： diamond abrasives,metal-bonded grinding wheel,manufacturability,Taguchi method,Selective laser melting (SLM)
更新于2025-09-23 15:19:57
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Robust design of type-2 fuzzy logic-based maximum power point tracking for photovoltaics
摘要： Photovoltaic (PV) power generation is uncertain and intermittent due to varying insolation and temperature. The Maximum Power Point Tracking (MPPT) algorithm implemented in a DC/DC converter ensures maximum PV power generation for a given insolation and temperature. This paper proposes a novel method to achieve this optimization under uncertainty: (1) An Interval Type-2 Fuzzy Logic System (IT2FLS) is used to tune the duty cycle of a DC/DC converter. The control gains and IT2 membership functions are tuned optimally using approximate gradient-descent algorithm. The so-called footprint of uncertainty (FOU) in the IT2 membership functions ensures that the IT2FLS is more powerful than traditional FLS in dealing with noise and uncertainty. (2) Taguchi’s orthogonal scenarios are used to evaluate the PV power generations by considering different meteorological conditions. Signal-to-noise ratios (SNR) obtained from Taguchi’s experiments are then analyzed by average effect of all control factor levels and main effect of each control factor to achieve the robust design of control gains and IT2 fuzzy membership functions. The proposed method is implemented using a DSP Chip-in-the-Loop (DIL) simulation through a real-time simulator OPAL-RT (OP5600) and TI DSP Chip (eZdsp TMS320F28335). A standalone PV system with a boost converter and load is used to demonstrate the practical applicability of the proposed method.
关键词： Maximum power point tracking,Taguchi method,Interval type-II Fuzzy logic,Photovoltaics
更新于2025-09-23 15:19:57