Integration of multivariate control charts and decision tree classifier to determine the faults of the quality characteristic(s) of a melt spinning machine used in polypropylene as-spun fiber manufacturing Part I: The application of the Taguchi method and principal component analysis in the processing parameter optimization of the melt spinning process

2021 ◽  
pp. 004051752098861
Author(s):  
Chung-Feng Jeffrey Kuo ◽  
Chang-Chiun Huang ◽  
Cheng-Han Yang
Keyword(s):  
Principal Component Analysis ◽  
Rotational Speed ◽  
Melt Spinning ◽  
Principal Component ◽  
Processing Parameters ◽  
Gear Pump ◽  
Processing Parameter ◽  
Spinning Process ◽  
Spun Fiber ◽  
Head Temperature

Melt spinning is the most extensively used method of fabricating polymeric fibers in the textile industry. This series of studies aimed to construct an automatic abnormality diagnosis system for polypropylene (PP) as-spun fiber produced by the melt spinning process. Part I of this study aimed to construct the processing parameter optimization for the PP as-spun fiber produced by the melt spinning machine. The product quality resulting from the processing parameters of the melt spinning process included six control factors: extruder temperature, gear pump temperature, die-head temperature, rotational speed of extruder, rotational speed of gear pump, and take-up speed. The quality characteristics included fiber fineness, breaking strength, breaking elongation, and modulus of resilience. The quality data were derived from the experiments, the design of which were based on the orthogonal array of the Taguchi method in order to calculate the signal-to-noise ratio, analysis of variance, and confidence interval. Principal component analysis was then applied to eliminate the multi-correlation of the output responses and transform the correlated responses into principal components, to obtain multi-quality optimum processing parameters. These optimum parameters, including the extruder temperature (180°C), gear pump temperature (220°C), die-head temperature (240°C), the rotational speed of the extruder (7.5 rpm), the rotational speed of the gear pump (15 rpm), and take-up speed (700 rpm) would later be used to build a prediction of an abnormality diagnosis system for identification of fault processing parameters in a melt spinning machine in Part II of this study.

The application of principal component analysis and gray relational method in the optimization of the melt spinning process using the cooling air system

2012 ◽  
Vol 83 (4) ◽  
pp. 371-380 ◽  
Author(s):  
Chung-Feng Jeffrey Kuo ◽  
Sheng-Siang Syu ◽  
Chien-Hung Lin ◽  
Kai-Ching Peng
Keyword(s):  
Principal Component Analysis ◽  
Melt Spinning ◽  
Principal Component ◽  
Component Analysis ◽  
Processing Parameters ◽  
Composite Fiber ◽  
Flow Equation ◽  
Optimal Parameters ◽  
Air System ◽  
Cooling Air

This study attempted to optimize the manufacturing process of polyethylene terephthalate (PET) and titanium dioxide-containing (TiO2) composite fibers. The composite fiber is made by the melt spinning processing method, and has the characteristics of the high strength of PET and the sterilization function of TiO2. To obtain the optimal processing parameters, this study applied the Taguchi method in planning the research experiment, and set one parameter of two levels and seven parameters of three levels using the L18 orthogonal array. The flow equation was used to design a cooling air system for the manufacturing, and the results showed that using one parameter of two levels can give a stable air pressure to cool the fiber to obtain the characteristics of excellent quality. Finally, field emission scanning electron microscope (FE-SEM) was used to observe the distribution of TiO2 particles in the PET fiber produced in the experiment, in order to verify the experimental effectiveness. This study used principal component analysis combined with the gray relational method to obtain the optimal parameters of the experiment, because the former has the advantage of data simplicity, while the latter can determine the factors influencing power ranking. Confirmation experiments were conducted to test the quality characteristics, and found that the properties of the fiber produced with the optimal parameters showed improvements.

Design Optimization of Processing Parameters for Polypropylene Fiber Based on the Taguchi Method

2012 ◽  
Vol 239-240 ◽  
pp. 1600-1603
Author(s):  
Shu Wen Wang ◽  
Te Li Su
Keyword(s):  
Melt Spinning ◽  
Breaking Strength ◽  
Signal To Noise Ratio ◽  
Polypropylene Fiber ◽  
Physical Nature ◽  
Processing Parameters ◽  
Processing Parameter ◽  
Effect Analysis ◽  
Main Effect ◽  
Spun Fiber

Melt spinning is the method that is most frequently used for manufacturing man-made fibers, while as-spun-fiber is the most important physical nature mainly of breaking strength for processing parameter will base on spinneret temperature, cooling temperature, cooling wind speed, and winding speed and so on to affect its physicality. First of all, suitable orthogonal arrays will be chosen to be applied on experiment plan to conduct experiment, and then it will work with SN (signal-to-noise) ratio and main effect analysis to appreciate the extent of impact of processing parameter on the quality, and confirm its reproducibility. As such, the optimized combination of processing parameters can be obtained.

Microstructure Analysis of Melt-Spun Al3Ti Intermetallics by XRD and EXAFS

1996 ◽  
Vol 460 ◽  
Author(s):  
Jinmin Chen ◽  
W. E. Frazier ◽  
E. V. Barrera
Keyword(s):  
Crystal Structure ◽  
High Temperature ◽  
Melt Spinning ◽  
Composition Range ◽  
Processing Parameters ◽  
Wheel Speed ◽  
Annealing Temperatures ◽  
Melt Spun ◽  
Temperature Heat ◽  
Spinning Process

ABSTRACTIn an effort to expand the composition range over which Al3Ti is stable, various amounts of niobium were substituted for titanium and processed by melt-spinning. Several samples were annealed both at 600°C and 1000°C for 24 hours. The effects of processing parameters such as wheel speed, the amount of niobium, and annealing temperatures on the structure were investigated by XRD and EXAFS. XRD showed that for all the samples the only structure present was DO22-The DO22 structure was stable even after the high temperature heat treatments. By means of EXAFS, niobium atoms were observed to occupy titanium sites in the DO22 structure. Furthermore, in the unannealed samples, increasing wheel speed of the melt spinning process or the niobium concentration tended to distort the crystal structure. It was observed that Ti EXAFS had different results from the Nb EXAFS beyond their occupying similar sites, which suggested there may exist some composition zones, i.e. rich Nb zone or rich Ti zones, although the structures present were still DO22. The samples were found to experience different distortions as a function of annealing temperatures.

scholarly journals Effective Formation of Well-Defined Polymeric Microfibers and Nanofibers with Exceptional Uniformity by Simple Mechanical Needle Spinning

Polymers ◽  
2018 ◽  
Vol 10 (9) ◽  
pp. 980 ◽  
Author(s):  
Hoik Lee ◽  
Yuma Inoue ◽  
Myungwoong Kim ◽  
Xuehong Ren ◽  
Ick Kim
Keyword(s):  
Polymer Concentration ◽  
Processing Parameters ◽  
Mechanical Force ◽  
Processing Parameter ◽  
Needle Size ◽  
Precise Control ◽  
Spinning Process ◽  
Facile Fabrication ◽  
Further Development ◽  
Highly Uniform

The fabrication of nanofibers with a mechanical force has attracted increasing attention owing to its facile and easy fabrication. Herein, we demonstrate a novel and facile fabrication technique with the mechanical force, needle spinning, which utilizes a needle tip to draw a polymer solution to form fibrous structures. We studied the effect of the processing parameters to the nanofiber structure, namely, the pulling away speed, pulling away distances, needle size, and polymer concentration, which were systemically controlled. As the needle spinning provides an effective route to adjust those parameters, highly uniform nanofibers can be achieved. There are clear tendencies in the diameter; it was increased as the polymer concentration and needle size were increased, and was decreased as the pulling away distance and pulling away speed were increased. Needle spinning with a precise control of the processing parameter enables us to readily fabricate well-defined nanofibers, with controlled dimensions in diameter and length; plus, single nanofibers also can be easily formed. Those features cannot be realized in common spinning process such as electrospinning. Therefore, this technique will lead to further development of the use of mechanical force for nanofiber fabrication and will expand the range of nanofibers applications.

Friction Stir Welding of Aluminum and Magnesium Alloys—Experimental Investigation and Optimization Using Hybrid Grey Relational Analysis and Principal Component Analysis

2018 ◽  
Vol 15 (2) ◽  
pp. 509-520
Author(s):  
D. Raguraman ◽  
D. Muruganandam ◽  
L. A. Kumaraswamidhas
Keyword(s):  
Principal Component Analysis ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Axial Load ◽  
Principal Component ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational

Friction stir welding of dissimilar materials is investigated experimentally in this work and optimization is performed by applying a hybrid Taguchi-Grey relational analysis-Principal component analysis to maximize the tensile strength and hardness of the weld bead. Two dissimilar metals AA6061 and AZ61 is friction stir welded and considered for the experimentation. Experimental matrix is designed using Taguchi's Design of Experiment (DOE). Optimum inputs rotational speed, axial load and transverse speed is obtained by applying the hybrid optimization technique. Statistical analysis of Multi Response Performance Index (MRPI) through Analysis of Variance (ANOVA) shows that axial load is the significant parameter that contributes by 75.67% towards MRPI, followed by transverse speed and rotational speed. Confirmation experiment with optimum condition produces a better friction stir welding joint with higher tensile strength and hardness.

Development of disperse dyes polypropylene fiber and process parameter optimization Part II: Dyeable polypropylene fiber production and melt spinning process parameter optimization

2017 ◽  
Vol 88 (13) ◽  
pp. 1505-1516 ◽  
Author(s):  
Chung-Feng Jeffrey Kuo ◽  
Wei-Lun Lan ◽  
Ming-Yan Dong ◽  
Shih-Hsiung Chen ◽  
Fang-Sian Lin
Keyword(s):  
Tensile Strength ◽  
Parameter Optimization ◽  
Melt Spinning ◽  
Polypropylene Fiber ◽  
Processing Parameters ◽  
Process Parameter ◽  
Disperse Dye ◽  
Process Parameter Optimization ◽  
Washing Fastness ◽  
Spinning Process

The industry uses color masterbatch mixing process and spinning for dope dyeing. There are color mending and color passivation appearance problems, and the process is inapplicable to functional apparel textiles. In this study, dyeable modified polypropylene (PP) fabric with disperse dye will be developed. The modified polyester material and PP for compounding processing with a compatibilizer will be used to make chips and the quality engineering method will be applied to analyze the optimum spinning process parameters. The fabric will be used to validate the dye washing fastness and light fastness in order to implement the dyeability of PP modified disperse dye. The optimum processing parameters to develop dyeable PP fiber will be studied. The modified materials are made into fiber by melt spinning, and the fuzzy C means technique is combined with the stem cells algorithm to design and analyze the processing parameters for the quality characteristics of tensile strength and elongation. The optimum fully drawn yarn is made. The tensile strength of the fiber of optimum parameter design is 3.66 g/d, higher than the 3.36 g/d of the pure PP fiber; the elongation is 38.65%, higher than the 36.66% of pure PP fiber, meaning the optimization method could improve the characteristics in melt spinning process, and conform with the standards of the textile industry. The fiber derived from the optimum parameters is woven into fabric for the disperse dyeing test and the validation of washing fastness shows the washing fastness is Level 3–4, meaning that the developed modified PP fabric has good dye-uptake and fastness.

scholarly journals Influence of Processing Parameters on the Thread and Spline Synchronous Rolling Process: An Experimental Study

Materials ◽  
2019 ◽  
Vol 12 (10) ◽  
pp. 1716
Author(s):  
Da-Wei Zhang ◽  
Bing-Kun Liu ◽  
Sheng-Dun Zhao
Keyword(s):  
Rotational Speed ◽  
Rolling Process ◽  
Processing Parameters ◽  
Geometric Parameters ◽  
Orthogonal Experimental Design ◽  
Processing Parameter ◽  
Forming Process ◽  
Experimental Conditions ◽  
Synchronous Rolling ◽  
Motion Parameters

The thread and spline synchronous rolling (TSSR) process is a new developed rolling process, which can form the different profiles simultaneously in the process and can ensure the consistency of the relative position of different profiles of parts. However, the multi-meshing motions are intercoupling and the multi-deformation characteristics are intercoupling during the forming process. It can easily result in dimension overshoot, and even does not make the synchronous rolling process go smoothly. Exploring the influence of controllable processing parameters on the synchronous rolling process, especially the geometric parameters of rolled parts, is helpful to determine the parameters and control the size error for a smooth rolling process. Thus, in this paper, the effects of controllable geometric parameters and motion parameters such as billet diameter, radial feed-in speed, and rotational speed of synchronous rolling die on the TSSR process have been studied. The synchronous rolling experimental scheme was determined using an orthogonal experimental design method, and the geometric parameters of different tooth profiles of rolled parts were measured and analyzed. The experimental results indicated that: the uncoordinated meshing movement between different tooth profiles is more likely to cause tooth error of the splined section of the part; variations of the processing parameters are more likely to cause fluctuations in the size of the splined section of the part, and change of the billet diameter mainly affects the outside diameter of the threaded and splined sections, and the threaded and splined pitches are mainly affected by the motion parameters of the synchronous rolling die; the motion parameters of the rolling die should be matched and the lower rotational speed needs to match the lower radial feed-in amount per revolution; the ideal dimensional accuracy can be obtained by using an appropriate processing parameter combination, for example, the pitch error of the splined section of the part is less than 0.5 μm under one set of experimental conditions in this paper.

scholarly journals Practical Applications of Taguchi Method for Optimization of Processing Parameters for Plastic Injection Moulding: A Retrospective Review

2013 ◽  
Vol 2013 ◽  
pp. 1-11 ◽  
Author(s):  
Ng Chin Fei ◽  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin
Keyword(s):  
Taguchi Method ◽  
Injection Moulding ◽  
Principal Component ◽  
Processing Parameters ◽  
Great Success ◽  
Processing Parameter ◽  
Practical Applications ◽  
Multiple Parameters ◽  
Plastic Injection Moulding ◽  
Plastic Injection

Determining the optimal processing parameter is routinely performed in the plastic injection moulding industry as it has a direct and dramatic influence on product quality and costs. In this volatile and fiercely competitive market, traditional trial-and-error is no longer sufficient to meet the challenges of globalization. This paper aims to review the research of the practical use of Taguchi method in the optimization of processing parameters for injection moulding. Taguchi method has been employed with great success in experimental designs for problems with multiple parameters due to its practicality and robustness. However, it is realized that there is no single technique that appears to be superior in solving different kinds of problem. Improvements are to be expected by integrating the practical use of the Taguchi method into other optimization approaches to enhance the efficiency of the optimization process. The review will shed light on the standalone Taguchi method and integration of Taguchi method with various approaches including numerical simulation, grey relational analysis (GRA), principal component analysis (PCA), artificial neural network (ANN), and genetic algorithm (GA). All the features, advantages, and connection of the Taguchi-based optimization approaches are discussed.

scholarly journals Hybrid Integration of Taguchi Parametric Design, Grey Relational Analysis, and Principal Component Analysis Optimization for Plastic Gear Production

2014 ◽  
Vol 2014 ◽  
pp. 1-11 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Principal Component Analysis ◽  
Process Parameters ◽  
Injection Moulding ◽  
Principal Component ◽  
Optimization Method ◽  
Processing Parameters ◽  
Hybrid Optimization ◽  
Relational Analysis ◽  
Shrinkage Behaviour ◽  
Grey Relational

The identification of optimal processing parameters is an important practice in the plastic injection moulding industry because of the significant effect of such parameters on plastic part quality and cost. However, the optimization design of injection moulding process parameters can be difficult because more than one quality characteristic is used in the evaluation. This study systematically develops a hybrid optimization method for multiple quality characteristics by integrating the Taguchi parameter design, grey relational analysis, and principal component analysis. A plastic gear is used to demonstrate the efficiency and validity of the proposed hybrid optimization method in controlling all influential injection moulding processing parameters during plastic gear manufacturing. To minimize the shrinkage behaviour in tooth thickness, addendum circle, and dedendum circle of moulded gear, the optimal combination of different process parameters is determined. The case study demonstrates that the proposed optimization method can produce plastic-moulded gear with minimum shrinkage behaviour of 1.8%, 1.53%, and 2.42% in tooth thickness, addendum circle, and dedendum circle, respectively; these values are less than the values in the main experiment. Therefore, shrinkage-related defects that lead to severe failure in plastic gears can be effectively minimized while satisfying the demand of the global plastic gear industry.

Sign in / Sign up

Export Citation Format

Share Document