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Application of Taguchi Method On Optimization of Testing Param 2013 Material
Application of Taguchi Method On Optimization of Testing Param 2013 Material
Technical Report
a r t i c l e i n f o a b s t r a c t
Article history: The target of this experimental study is to investigate solid particle erosion behavior of a new composite
Received 20 July 2012 material formed by adding boric acid particles to glass fibers and epoxy resin at an amount of 15% and
Accepted 10 November 2012 30%. The tests which involved angular aluminum particles with two different sizes were conducted at dif-
Available online 28 November 2012
ferent conditions of impact velocities, fiber directions and impingement angles. The test specimens were
characterized by techniques of X-ray diffraction (XRD) and scanning electron microscope (SEM). In addi-
tion, the design of the experiments which utilizes Taguchi’s orthogonal arrays approach was used and an
optimal parameter combination determined which led to minimization of erosion rate of the composites.
Crown Copyright Ó 2012 Published by Elsevier Ltd. All rights reserved.
0261-3069/$ - see front matter Crown Copyright Ó 2012 Published by Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.matdes.2012.11.024
M. Bagci, H. Imrek / Materials and Design 46 (2013) 706–712 707
Biswas and Satapathy [10] established a mathematical model 2. Experimental setup and procedure
for estimating erosion damage caused by solid particle impact on
red mud filled glass fiber reinforced epoxy matrix composites 2.1. Test materials
and also found a correlation derived from the results of Taguchi
experimental design. The filler content in the composites, temper- New composite materials where boric acid particles were added
ature of the erodent particles, the impingement angle and velocity to glass fiber and epoxy resin at an amount of 15% and 30% used in
are found to have substantial influences in determining the rate of this experimental study were industrially produced at Izoreel
material loss from the composite surface due to erosion. Composite Insulating Materials, a Turkish Materials Company
Tsuda et al. [11] investigated sand erosion behavior and wear where ‘‘hand lay-up’’ technique is used to fabricate the composites.
mechanism of various types of glass fiber reinforced plastics. Ero- The GF/EP composite test specimens were obtained as a result of
sion behavior of fiber reinforced plastics changed from ductile reaction between polyphenol epychloridine with alkaline condi-
manner to brittle one with increase of glass fiber content, and ero- tions. Apart from showing relatively high mechanical strengths at
sion rate was max at vertical impact for higher glass fiber content room temperature, the materials exhibit good dielectric loss and
FRP. electrical strengths in dry and moisturized environments. The
Patnaik et al. [12] scrutinized the solid particle erosion wear composites have high chemical resistance and can harden at both
performance of a multi component hybrid composite consisting low and high temperatures. Moreover, test specimens were cut
of polyester, glass fibers and alumina particles. In this study, a with a diamond saw into plates having thicknesses of 3 mm and
mathematical model for damage assessment in erosion has been cross sections of 30 30 mm2 suitable to fit onto the specimen
developed and validated by a well designed set of experiments. holder of the test device. They were then located to the specimen
For this, the design approach of the experiments employed the holder on the device. In addition to all these details which define
Taguchi’s orthogonal arrays method. The study reveals that the test specimens, the XRD patterns were obtained in order to
glass–polyester composite without any filler suffers greater ero- prove the presence of the added boric acid additive into the struc-
sion loss than the hybrid composite with alumina filling. Signifi- ture. The presence of the boric acid additive is clearly seen on the
cant control factors and their interactions that influence the wear Fig. 1.
rate are identified.
Sınmazcelik and Tasßkıran [13] characterized the solid particle
erosion behavior of randomly oriented short glass fiber and min- 2.2. Erosion testing
eral particle reinforced polyphenylenesulphide (PPS) composites.
The erosion rates of these composites have been evaluated at dif- During the erosion wear tests, the ASTM: G76-07 standard test
ferent impingement angles and at three different particle speeds. method was used. This is the method that involves dry and com-
The PPS composites showed semi-ductile erosion behavior, with pressed air accelerating the solid particles to strike the specimen
maximum erosion rate at 60° impingement angle. surfaces. The test apparatus [16] which was specifically designed
In a study conducted by Suresh et al. [14] solid particle erosion for the tests consists of a main reservoir, pressurized particle tank,
behavior of polyetherketone reinforced by short glass fibers with universal valves, manometers, flow control and pressure regula-
varying fiber content (0–30 wt%), was investigated. Here, the tors, nozzle, specimen holder, recycling box and a compressor.
researchers evaluated different impact angles (15–90°) and impact The particles impact velocities used in the tests were adjusted by
velocities (25–66 m s1) using silica sand particles as abrasives. using the double disk method in which two disks were connected
PEK and its composites exhibited maximum erosion rate at 30° im- to a common shaft from a driving prime mover [17]. The impinge-
pact angle indicating ductile erosion behavior. The erosion rates of ment angle, one of the most important parameters affecting solid
PEK composites increased with increase in amount of glass fiber. particle erosive wear, was varied by turning the test specimen
Srivastava and Pawar [15] determined the effects of fly-ash fil- holder around its own axis. In addition, angular aluminum abrasive
ler, impingement angle and particle velocity on the solid particle particles were used as eroding agents and two different fiber direc-
erosion behavior of E-glass fiber reinforced epoxy composites. tions were preferred. Properties of test specimens are given in
The result shows semi-ductile erosion behavior with maximum Table 1.
erosion rate at 60° impingement angle. The erosion rate displays
a strong dependence on impact velocity. They found that erosive 2.3. Experimental design
wears of GFRP composite with 4 g flyash as filler is the lowest. This
filler restricts fiber–matrix de-bonding. They also concluded that To select an appropriate orthogonal array for experiments, the
neat glass epoxy without any filler exhibits the highest erosion rate total degrees of freedom need to be computed [18]. The degrees
due to weak bonding strength. of freedom are defined as the number of comparisons between
In this experimental study, neat glass fiber-reinforced epoxy process parameters that need to be made to determine which level
resin composites were selected as the main test specimen and is better and specifically how much better it is [19,20]. In the pres-
then boric acid was added into this neat structure as a filler ent study, the interaction between the solid particle erosion wear
material at an amount of 15% and 30% of resin and thereby parameters is included. In this case, there are 34° of freedom owing
new glass fiber reinforced epoxy resin composite materials were to the five erosion parameters and the interactions between
formed; then, erosion wear behavior of these materials were parameters. Once the degrees of freedom required are known,
investigated under different impact velocities (23, 34 and the next step is to select an appropriate orthogonal array to fit
53 m s1) and by using aluminum erodent particle sizes of the specific task. In this study, an L36 (22 33) orthogonal array
200 and 400 lm and at impingement angles of 30°, 60° and was used. Each solid particle erosion wear parameter is assigned
90° along the fiber directions of 0° and 45°. Taguchi’s orthogonal to a column where 108 erosion parameter combinations are avail-
arrays approach is used for the design of the experiments and an able. A total of 36 experimental runs must be conducted, using the
optimal parameter combination is determined, which leads to combination of levels for each control factor as indicated in Table 2.
minimization of erosion rate. At the end of the tests, graphs of Moreover, the results of the experiments are reported in the com-
S/NL ratios based on the test variations were obtained and re- pleted design layout as seen in Table 2. Analysis of the influence of
lated comments were made. each erosion parameter was performed by using MINITAB 16.
708 M. Bagci, H. Imrek / Materials and Design 46 (2013) 706–712
Fig. 1. XRD patterns of GF/EP (Neat), GF/EP (15% boric acid) and GF/EP (30% boric acid) test specimens.
mal testing conditions of these control factors can be very easily 17 0 400 15 90 23 10.94
determined from the S/NL response graph. It is evident that the ef- 18 0 400 30 30 34 15.32
19 45 200 0 60 23 1.87 5.4368
fect was different for each type of the composite. It was found that 20 45 200 15 90 34 11.23 21.0076
the test specimens with 45° fiber directions recorded lower erosion 21 45 200 30 30 53 11.39 21.1305
rates than the specimens with 0° fiber directions. The force of abra- 22 45 200 0 60 34 3.06 9.7144
sive particles had directly affected the fibers which ultimately im- 23 45 200 15 90 53 10.75 20.6282
24 45 200 30 30 23 4.02 12.0845
posed bending moments on the fibers [21]. As the particle flow
25 45 200 0 90 34 2.13 6.5676
increased, delamination of fibers off the surface was more easily. 26 45 200 15 30 53 44.17 32.9025
When the graphs are studied, it is seen that regardless of the fact 27 45 200 30 60 23 1.61 4.1365
the five graphs are at different values, the specimens in both sets 28 45 400 0 90 34 2.18 6.7691
of graphs seem to undergo much erosion rates at impingement an- 29 45 400 15 30 53 54.30 34.6960
30 45 400 30 60 23 2.04 6.1926
gle of 30°. Because, at 30° impingement angle, the erosion affected 31 45 400 0 90 53 2.99 9.5134
zone was found to be more intense and a plough was formed 32 45 400 15 30 23 21.39 26.6042
across the surface. At 90° impingement angle, the surface deforma- 33 45 400 30 60 34 3.35 10.5009
tion is relatively narrow. However; beside these effects, the wear 34 45 400 0 90 23 1.58 3.9731
35 45 400 15 30 34 45.18 33.0989
rate recorded at 90° impingement angle was still at relatively mild
36 45 400 30 60 53 4.03 12.1061
level as compared to that on a 30° angle. This negative aspect
M. Bagci, H. Imrek / Materials and Design 46 (2013) 706–712 709
Fig. 2. The graphs of S/NL ratio vs. fiber direction, erodent size, material, impingement angle and impact velocity.
Fig. 3. The interaction graphs of S/NL ratios vs. direction, size, material, angle and velocity.
710 M. Bagci, H. Imrek / Materials and Design 46 (2013) 706–712
Table 4 Table 5
Results of the confirmation tests. Analysis of variance for S/NL ratios.
Initial wear Optimal wear parameters Source DF Seq. SS Adj. SS Adj. MS F Contribution
parameters (%)
Experiment Prediction
Direction 1 27.91 27.91 27.912 8.57 1.07
Level A1B1C1D1E1 A2B1C3D3E1 A2B1C3D3E1
(A)
Erosion rate (mg/ 5.07 1.28 0.95
Size (B) 1 40.69 40.69 40.692 12.50 1.56
kg)
Material (C) 2 1364.39 1066.43 533.217 163.76 52.51
S/NL ratio (dB) 14.1 2.14 0.41
Angle (D) 2 874.05 817.12 408.560 125.47 33.63
Improvement of S/NL ratio = 14.51. Velocity (E) 2 222.98 222.98 111.489 34.24 8.58
Residual 21 68.38 68.38 3.256 2.63
error
The control factors were sorted in relation to the differences in Total 29 2598.41
values. The S/NL ratios response of the erosion rate for test speci-
mens is presented in Table 3. This experimental study has shown
that the most effective influence on erosive wear rate appears calculated. Usually, when F > 4 it means that the design parameter
due to be variations on the materials used for the specimens. That showed a significant effect on the optimal characteristic.
is, the varying rates of boric acid additives into the main structure The last column of Table 5 also indicated the percentage of each
caused the resulting composite material to exhibit different resis- factor contribution on the total variation, thus exhibiting the de-
tances against wear; and it was found that, this (boric acid addi- gree of influence on the results. It might be observed in this table
tive) has been the most effective parameter among the others. that the material factor (52.51%), the impingement angle factor
After this parameter, the variation of impingement angle follows (33.63%) and the impact velocity (8.58%) had a significant influence
suit. It was found that any changes in these angles caused signifi- on the erosion rate of GF/EP composites while the erodent particle
cant variations on wear rates. Striking speed, size of the erosive size (1.56%) and the fiber direction (1.07%) had no significant ef-
particles and fiber directions come after these first two parameters, fects on it.
by playing a determining role in increasing wear rates but with
decreasing magnitude down the parameter list.
4. Conclusions
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