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EN
This work aims to join sheets of carbon steel to aluminum alloy AA6061. A lap joint arrangement was used with a joint lap area of dimensions *25 25 mm . The joining procedure was carried out using a rotating tool of 10 mm shoulder diameter. Three process parameters, with three levels for each parameter, were selected to investigate their effects on joints quality. The parameter’s levels for each experiment were designed using the design of the experiment method (DOE). The results indicated that the two materials were joined by a mechanical interlock at an interface line, without formation of intermetallic compounds. The shear force of the joint reached an ultimate value of .4 82kN . The shear force of the joint improved by increasing plunging depth of the tool. Samples of minimum shear force value failed by a pull-outing aluminum metal from the carbon steel specimen. Samples of higher shear force value exhibited a shear mode of fracture. Increasing the rotating speed and decreasing pre-heating increased the process temperature.
EN
The resistance spot welding (RSW) method was used to join aluminum alloy AA 1050 and copper alloy UNS C50100 sheets. Mechanical properties of the joints were examined. The influence of welding process parameters on tensile shear force of the joints was discussed. The design of experiments (DOE) method was used to analyze the influence of welding parameters on the mechanical properties of the joints. Three RSW parameters were used: welding current, squeeze time, and welding time. The results showed that the joint shear stress increased with increasing the welding current until a value of 12000 Amp. Then the shear stress decreased. The tensile shear stress increased with increasing the welding and squeeze time. As a consequence, it can be possible to weld copper with aluminum by RSW.
EN
Optimal parameters setting of injection moulding (IM) machine critically effects productivity, quality, and cost production of end products in manufacturing industries. Previously, trial and error method were the most common method for the production engineers to meet the optimal process injection moulding parameter setting. Inappropriate injection moulding machine parameter settings can lead to poor production and quality of a product. Therefore, this study was purposefully carried out to overcome those uncertainty. This paper presents a statistical technique on the optimization of injection moulding process parameters through central composite design (CCD). In this study, an understanding of the injection moulding process and consequently its optimization is carried out by CCD based on three parameters (melt temperature, packing pressure, and cooling time) which influence the shrinkage and tensile strength of rice husk (RH) reinforced low density polyethylene (LDPE) composites. Statistical results and analysis are used to provide better interpretation of the experiment. The models are form from analysis of variance (ANOVA) method and the model passed the tests for normality and independence assumptions.
4
Content available remote Optymalizacja procesów jednostkowych w technologii organicznej
PL
Wykorzystanie metod projektowania eksperymentów oraz optymalizacji operacji jednostkowych znajduje coraz większe zastosowanie w dziedzinie inżynierii chemicznej, z powodu coraz większego zapotrzebowania na tworzenie racjonalnych i zrównoważonych procesów technologicznych. Inżynier procesowy, dzięki nowoczesnym modelom obliczeniowym, może z powodzeniem zaimplementować planowanie eksperymentu już na wczesnym etapie prac z zakresu badań i rozwoju oraz optymalizacji całych procesów technologicznych, uzyskując założone cele w znacznie krótszym czasie. Przedstawiono zarys kryteriów postępowania przy planowaniu i optymalizacji procesów oraz opis powszechnie stosowanych modeli optymalizacyjnych wraz z ich porównaniem.
EN
The methods of designing expts. and optimization of unit operations were presented. The criteria that should be followed in the design and optimization of expts. and processes were discussed. Commonly used optimization models such as full factor design, fractional factor design, central composite design, optimal design, Taguchi design, Box-Behnken method and optimal planning models were described and compared.
EN
The introduction of solutions conventionally called Industry 4.0 to the industry resulted in the need to make many changes in the traditional procedures of industrial data analysis based on the DOE (Design of Experiments) methodology. The increase in the number of controlled and observed factors considered, the intensity of the data stream and the size of the analyzed datasets revealed the shortcomings of the existing procedures. Modifying procedures by adapting Big Data solutions and data-driven methods is becoming an increasingly pressing need. The article presents the current methods of DOE, considers the existing problems caused by the introduction of mass automation and data integration under Industry 4.0, and indicates the most promising areas in which to look for possible problem solutions.
EN
Composting is a natural process; however, many artificial factors have been developed to improve process efficiency for the organic fraction of municipal solid waste (OFMSW) stabilization in the mechanical-biological treatment (MBT) plant. The study aimed to assess the effect of aeration (X1), irrigation (X2), process time (X3) and turning frequency (X4) on OFMSW stabilization after the intensive degradation phase of compositing in a full-scale MBT plant. The four-factorial design on two levels with two replicates was used to the optimization of compost stabilization yield. Among analyzed factors, mechanical turning was found not to significantly influence the effect of stabilization. The achieved determination coefficient (R2) of 0.94 suggests an adequate representation of the process model and a good correlation between the experimental and predicted values. The achieved stabilization yield obtained in the control run was 47.5%, where the aeration (X1) was set up as blower working cycle: 10 minutes blowing and 5 minutes break, the irrigation level (X2) was set up for 10000 dm3/d and process was performed 4 weeks (X3).
PL
Kompostowanie to zachodzący naturalnie tlenowy proces biodegradacji wykorzystywany przemysłowo zwłaszcza do przetwarzania odpadów. Opracowano i określono wiele parametrów tego procesu w celu poprawy wydajności procesu stabilizacji frakcji organicznej odpadów komunalnych (OFMSW) w zakładzie obróbki mechaniczno-biologicznej (MBT). Niniejsza praca miała na celu ocenę wpływu napowietrzania (X1), nawadniania (X2), czasu trwania procesu (X3) i częstotliwości przewracania pryzmy (X4) na stabilizację OFMSW uzyskanej po intensywnej fazie kompostowania w zakładzie MBT. Do optymalizacji wydajności stabilizacji kompostu wykorzystano czteroczynnikowy plan eksperymentu (DOE) na dwóch poziomach z dwoma powtórzeniami. Stwierdzono, że mechaniczne przewracanie pryzmy nie ma statystycznie istotnego wpływu na efektywność stabilizacji. Osiągnięty współczynnik determinacji (R2) wynoszący 0,94 sugeruje odpowiednią reprezentację modelu procesu i dobrą korelację między wartościami eksperymentalnymi i przewidywanymi. Uzyskana wydajność stabilizacji uzyskana w przebiegu kontrolnym wyniosła 47,5%, przy ustawieniu czasów pracy wentylatora napowietrzania jako 10 minut działania i 5 minut przerwy (X1), nawadniania na poziomie 10 000 l/dobę (X2) i eksperymencie trwający, 4 tygodnie (X3).
7
Content available Use the doe method for tool durability increase
EN
Constantly improving, which is one of the principles of quality management is the base for good understanding, behaviour of individual processes, investigating variability and impact on its the process. The aim of every business is to increase profits. Reducing the cost of tools can also contribute to this. Utilising the DOE method to reduce the durability of removable cutting plate, as describe the article, is one of way, how to apply this method in practice. The DOE method enables find factors that are the most relevant to the production process and determine their best values. Using this method, you can set the selected inputs so that, the process achieves the desired results with maximum stability and resilience. The article contains a brief overview of Minitab software by which the collected process data was analysed. The core of the article describes how to solve the problem using the singular phases of the DMAIC cycle. Each of these phases has its own specific aim, which logically defines what activities each step is aimed at. DMAIC is extended variant of the process improvement model based at the Deming circle PDCA. Six sigma methodology is used as a standard procedure for project planning and realisation. At the end of an article is described that by increase durability of removable cutting plate the problems found in the analysis of the current condition that have been validated by a case study in the company have been eliminated.
EN
The paper presents the method of simplified parametric analysis of the sensitivity of a pre-tensioned concrete beam. The presented approach is based on the DOE (design of experiments) data collection which is simulation technique allowing for identification of variables deciding about the effectiveness and costs of designed structures. Additionally, application of the hyper-surface of the construction response allows designers to the development of multi-dimensional trade-off graphs to facilitate, the assessment of the scope of changes in random state variables permitted due to the adequate criteria and selection of their values close to optimum. Design basics, procedures and results of the presented considerations of sensitivity assessment and reliability of the structure has been shown on the example of a pre-stressed concrete beam designed in accordance with the requirements and procedures of Eurocode 2.
PL
W artykule przedstawiono metodę analizy wpływu zmiennych wejściowych na parametry charakteryzujące stan konstrukcji sprężonych w początkowej i trwałej sytuacji obliczeniowej, opartą na symulacjach komputerowych i technice zbierania informacji DOE (Design Of Experiments). Założenia, procedury i wyniki zastosowania techniki DOE przedstawiono na przykładzie belki strunobetonowej zaprojektowanej zgodnie z wymaganiami Eurokodu 2. Przeprowadzono analizę typu „what-if” wpływu wartości obciążenia i siły sprężającej w poszczególnych cięgnach (uwzględniając straty wynikające z relaksacji stali sprężającej) oraz modułu sprężystości podłużnej betonu na nośność graniczną i maksymalne ugięcie belki.
EN
This work presents a procedure for bearing degradation monitoring at an early stage. The analysis of variance (ANOVA) coupled with Tukey’s test is used to single out the suitable parameters to follow the fault size evolution ranging from 50 µm to 150µm. The Tukey's criterion is adopted in this case to study the ability of time and frequency indicators. The rotational speed, centrifugal load and fault size are considered as independent variables while the time and frequency indicators are taken as dependent variables. The experiments are performed on bearings having a fault on outer race. Based on the results of this study, the Kurtosis and Skewness show a good ability to assess the evolution of degradation in the bearings at an early stage. The paper discusses the weakness of the time and frequency indicators.
EN
The present study explores the influence of variables like particle size of coal, load, speed and sliding distance on weight loss in manganese-steel (Mn-steel). The observations are made using pin-on-disc apparatus. Specimen prepared from Mn-steel used for the wear test. The size and shape of specimen is in accordance with ASTM G99 standard. From design of experiment (DOE) procedure the variables load were altered to assess the weight loss in material. It is observed that with the increase in particle size and load, the weight loss increases when other variables are constant. Mn-steel shows decrease in weight loss at higher load due to property of dipole interaction and stacking fault energy (SFE). Decrease in weight loss at higher load results in transition in wear mechanism from scratch to groove formation as observed under field emission scanning electron microscope (FESEM).
PL
Przedstawiono wyniki badań doświadczalnych procesu otrzymywania nanosfer polilaktydowych zawierających chlorofenezynę, otrzymywanych metodą emulsyjną z odparowaniem rozpuszczalnika. Cząstki te mogłyby być wykorzystywane jako przeciwgrzybicze systemy leków o kontrolowanym czasie uwalniania. Stosując metodę planowania doświadczeń uzyskano równanie regresji opisujące wpływ wybranych parametrów procesu na rozmiar sfer. Określono warunki otrzymywania cząstek o rozmiarze poniżej 100 nm.
EN
Research results dealing with the preparation of polylactide nanospheres containing ehlorphenesin are presented. Polylactide nanospheres were prepared by the emulsification method with solvent evaporation. These particles could be used commercially as the antifungal drug delivery system. An influence of selected process parameters on the spheres’ size was determined. The regression equation was predicted using the mathematical method of experiment design (DOE). The particles of size smaller than 100 nm were obtained.
EN
The aim of this paper is to present methods of digitally synthesising the sound generated by vibroacoustic systems with distributed parameters. A general algorithm was developed to synthesise the sounds of selected musical instruments with an axisymmetrical shape and impact excitation, i.e., Tibetan bowls and bells. A coupled mechanical-acoustic field described by partial differential equations was discretized by using the Finite Element Method (FEM) implemented in the ANSYS package. The presented synthesis method is original due to the fact that the determination of the system response in the time domain to the pulse (impact) excitation is based on the numerical calculation of the convolution of the forcing function and impulse response of the system. This was calculated as an inverse Fourier transform of the system’s spectral transfer function. The synthesiser allows for obtaining a sound signal with the assumed, expected parameters by tuning the resonance frequencies which exist in the spectrum of the generated sound. This is accomplished, basing on the Design of Experiment (DOE) theory, by creating a meta-model which contains information on its response surfaces regarding the influence of the design parameters. The synthesis resulted in a sound pressure signal in selected points in space surrounding the instrument which is consistent with the signal generated by the actual instruments, and the results obtained can improve them.
13
Content available The Investigation of Conductive Via Properties
EN
The investigation ofthe Low Temperature Co-fired Ceramic (L TCC) via filling process quality is presented in this paper. The goal of this paper was to propose and to validate a way of the verification whether the L TCC fabrication was conducted correctly. The work presents an application of the Design of the Experiment (DoE) methodology in such validation and discusses usefulness and drawbacks of the chosen solution. The optimized technology of via filling will be applied in the fabrication of tactile displays for blind people.
14
Content available remote Impact of processing parameters on the LTCC channels geometry
EN
A great advantage of Low Temperature Co-fired Ceramics (LTCC) yields the possibility of channel and air cavity fabrication. Such empty spaces have numerous applications, for example, in microfluidics, microwave techniques and integrated packaging. However, improper geometry of these structures can degrade the performance of the final device. The processing parameters recommended by the LTCC tape supplier are relevant for the production of multilayer circuits but not surface embedded channels and/or cavities. Thus, it is important to examine which factors of the fabrication process are the most significant. In our study, special attention has been paid to the geometric performance of the channel structure resulting from the applied processing parameters. Laser cutting parameters were checked to obtain the structures with great fidelity. The impact of an isostatic lamination on the quality of the final structure was analyzed. The influence of pressure and temperature of the lamination process on the channel geometry and tape shrinkage were examined. The performed experiments showed that some improvements in channel/cavity geometry may be achieved by optimizing the processing procedures. The microscopic observations combined with the Analysis of Variance (ANOVA) showed which combinations of the processing parameters are the best for achieving a channel/cavity structure with the desired geometry.
EN
Businesses, which typically operate in highly changeable settings, are forced to make constant adjustments to meet legislative requirements concerning employment and the performance of work. To that end, they need to identify tools for improving their work processes. By employing quality management methods to upgrade their working environments, enterprises gain the ability to satisfy the needs and expectations of their customers, including the internal customers who rely on the processes carried out by their employees. The effort not only helps them boost the quality, reliability, flexibility and cost-efficiency of their processes but also allows them to comply with legislative/regulatory requirements. In doing so, they bring their system into conformity with any safety policies that are in place in their organizations. The article discusses the option of employing quality-oriented process design methods (FMEA, QFD and DOE) to improve working environments. The author describes some of the basic prerequisites for their use aimed at boosting the planning and deployment of improvement measures in areas related to the working environment.
PL
W artykule, zgodnie z „podejściem procesowym” ISO 9000, wykazana została konieczność stworzenia systemu monitoringu i kontroli podziemnego magazynowania gazu, w tym: obiektów, parametrów, metod, częstotliwości działań naprawczych, który wykonany zostanie na podstawie wzoru strukturalnego cyklu monitoringu. Podejście jakościowo-wskaźnikowe pozwala na definiowanie złożonych kryteriów oszacowania efektywności działania, które będą pomocne w podejmowaniu skutecznych decyzji w zakresie zarządzania w odpowiednim czasie, w tym również z punktu widzenia ochrony środowiska.
EN
This paper deals with determination of optimal injection molding process parameters by DOE technique. Taguchi’s orthogonal table was applied to plan the simulation and the experiments. For this study plastic simulation of injection molding for specimens made of fiber glass filled PBT was performed . Determination of the optimal process parameters was based on RSM surface with goal of minimization moldings warpage. Five controlling factors of melt temperature, coolant inlet temperature, injection and packing and cooling time, packing pressure and packing time with three levels for each factor were selected. According to the results, melt temperature is the most important parameter for both moldings. Injection time and coolant inlet temperature had no significant effect on the shrinkage of either moldings.
PL
Artykuł skupia się na określeniu za pomocą metody DOE optymalnych parametrów procesu formowania wtryskowego. Do planowania symulacji i eksperymentu zastosowano ortogonalną tablicę Tagucjiego. Symulację wykonano dla procesu formowania wtryskowego włókna szklanego wypełnionego tworzywem PBT. Optymalne parametry procesu zostały przedstawione za pomocą tzw. „powierzchni odpowiedzi” (RSM) w celu określenia minimalnego zwichrowania wyprasek. W badaniach uwzględniono pięć parametrów sterowalnych: temperaturę wtrysku, temperatura chłodziwa, czas wtrysku-docisku-studzenia oraz ciśnienie i czas docisku. Wartości tych parametrów podzielono na trzy poziomy. W odniesieniu do wyników, temperatura wtrysku jest najważniejszym parametrem. Natomiast czas wtrysku oraz temperatura chłodziwa nie mają istotnego znaczenia na skurcz wypraski.
EN
This paper presents a multi-objective extended optimization methodology applied in the machining of a randomly oriented GFRP rod. Design of Experiment (DOE) has been selected based on a L9 orthogonal array design with varying process control parameters like: spindle speed, feed rate and depth of cut. Multiple surface roughness parameters of the machined FRP product along with the Material Removal Rate (MRR) of the machining process have been optimized simultaneously. The Fuzzy Inference System (FIS) has been proposed for providing feasible means for the meaningful aggregation of multiple objective unctions into an equivalent single performance index (MPCI). This Multi-Performance Characteristic Index (MPCI) has been optimized using the Taguchi method. The approach adapted here is capable of overcoming limitations/assumptions of existing optimization methodologies available in the literature.
EN
As many research focused on robustness methodology, this paper discuss on how to implement these methodology concept from the management perspective. Guidelines and appropriate strategies are discussed on Quality Engineering (QE) implementation in an organization and experimentation. Firstly, the experience of a company implementing QE is presented. Secondly, the practical data of a laboratory experiment is discussed in order to relate between the experimental result and requirement in industry. The QE implementation is explained on the strategies used in tackling organization problems. Optimization of peel adhesion strength test is carried out to propose the feasibility of experimental design tools. QE methodology between the practical case and company's case study is compared. Finally, through the QE implementation in organization and method applied in experimental design, a framework is proposed for QE methodology. QE implementation is presented from two sources, from a company and practical case study point of view. It helps a researcher or engineer applies the management strategy and engineering tool to ensure product robustness.
19
EN
Purpose: The first aim of this paper is to optimize pneumatic actuator behavior using a structured approach to define and control system factors in order to achieve targeted output values. The second aim is to present a structured optimization process supported by Measurement System Analysis (MSA) and Design of Experiment (DOE) tools in practical applications. Design/methodology/approach: A complete approach for optimizing an unknown system with a structured approach known from DFSS methodology is used in the practical example of pneumatic actuators. DFSS methodology requires a detailed project definition, but ensures good quality of measurement data and a well-prepared optimization process supported by known DOE tools. Findings: The structural approach for system optimization known from DFSS methodology provides a good fit for the optimization of a pneumatic actuator to achieve specified targets. Teams working on system optimization not only set the parameters but also gather a large amount of valuable information about how the mentioned system works, and what the main factors influencing the final results are. The gathered knowledge can be used to create a robust design with the lowest possible cost. Research limitations/implications: The results obtained from Measurement System Analysis and Design of Experiment are valid only for chosen factors and, importantly, only in the range used in both statistical methods. Extrapolation outside the statistical model boundaries is forbidden. Therefore a critical aspect is to agree within the project team on the correct factors and their levels. Practical implications: The optimization of pneumatic actuators can be achieved by a structured approach consisting mainly of project definition, measurement system analysis and final optimization through DOE tools to achieve given targets for displacement and time simultaneously. Originality/value: First Time Through optimization of a pneumatic actuator system as an example of any system treated as a black box, meaning a system with an unknown relationship between input and output. Design for Six Sigma methodology presented in a practical approach.
EN
Kompania Piwowarska SA has a population of 140 million of returnable beer bottles. These bottles are classified and after positive evaluation are washed and refilled. It is necessary to perform periodic estimation of class distribution in a general population of bottles in view of future new bottles order. The authors proposed computer simulation basing on real information of distribution taken from Kompania's archives. It was very optimistic because it allows reduction of sample size about nine times in comparison with the first estimation of Kolmogorov's distribution.
PL
Kompania Piwowarska SA wykorzystuje w dystrybucji populację 140 milionów butelek zwrotnych, których stan jest oceniany i po pozytywnej klasyfikacji są myte i ponownie napełniane. Niezbędne jest dokonywanie okresowych ocen liczebności poszczególnych klas butelek, aby zamówić dostawę nowych z odpowiednim wyprzedzeniem. Autorzy zaproponowali symulację komputerową opartą na rzeczywistych danych uzyskanych z archiwów Kompanii. Uzyskane wyniki pozwoliły na niemal dziewięcioletnią redukcję rozmiaru próby w porównaniu z teoretycznym oszacowaniem z rozkładu Kołmogorowa.
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