Incorporation of Taguchi approach with CFD simulations on laser welding of spacer grid fuel rod assembly

Satyanarayana, G.; Narayana, K. L.; Rao, B. Nageswara

doi:10.1016/j.mseb.2021.115182

Cited by 18 publications

(16 citation statements)

References 36 publications

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“…The modified Taguchi approach has been extensively evaluated for its effectiveness (Anantha et al, 2023;Buddi et al, 2018a;Dharmendra et al, 2019;Koneru et al, 2022;Rajyalakshmi and Boggarapu, 2019;Satyanarayana et al, 2019Satyanarayana et al, , 2021, with a particular comparison made in (Rajyalakshmi and Nageswara Rao, 2019) against the optimal solutions obtained using a genetic algorithm (GA) and an ensemble of meta-models (EMs) (Zhou et al, 2018) as presented in (Chaudhry and Ahmed, 2014). Furthermore, Chaudhry and Ahmed (2014) introduced a spreadsheet-based GA method specifically designed for optimizing the initial design of aircraft.…”

Section: Mmms 201mentioning

confidence: 99%

Multi-objective optimization to specify optimal selective laser melting process parameters for SS316 L powder

Prasanth Kumar,

Boggarapu,

Narayana Murty

2023

MMMS

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PurposeThis paper adopts a modified Taguchi approach to develop empirical relationships to the performance characteristics (output responses) in terms of process variables and demonstrated their validity through comparison of test data. The method suggests a few tests as per the orthogonal array and provides complete information for all combinations of levels and process variables. This method also provides the estimated range of output responses so that the scatter in the repeated tests can be assessed prior to the tests.Design/methodology/approachIn order to obtain defect-free products meeting the required specifications, researchers have conducted extensive experiments using powder bed fusion (PBF) process measuring the performance indicators (namely, relative density, surface roughness and hardness) to specify a set of printing parameters (namely, laser power, scanning speed and hatch spacing). A simple and reliable multi-objective optimization method is considered in this paper for specifying a set of optimal process parameters with SS316 L powder. It was reported that test samples printed even with optimal set of input variables revealed irregular shaped, microscopic porosities and improper melt pool formation.FindingsFinally, based on detailed analysis, it is concluded that it is impossible to express the performance indicators, explicitly in terms of equivalent energy density (E_0ˆ*), which is a combination of multiple sets of selective laser melting (SLM) process parameters, with different performance indicators. Empirical relations for the performance indicators are developed in terms of SLM process parameters. Test data are within/close to the expected range.Practical implicationsBased on extensive analysis of the SS316 L data using modified Taguchi approach, the optimized process parameters are laser power = 298 W, scanning speed = 900 mm/s and hatch distance = 0.075 mm, for which the results of surface roughness = 2.77 Ra, relative density = 99.24%, hardness = 334 Hv and equivalent energy density is 4.062. The estimated data for the same are surface roughness is 3.733 Ra, relative density is 99.926%, hardness is 213.64 Hv and equivalent energy density is 3.677.Originality/valueEven though equivalent energy density represents the energy input to the process, the findings of this paper conclude that energy density should no longer be considered as a dependent process parameter, as it provides multiple results for the specified energy density. This aspect has been successfully demonstrated in this paper using test data.

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Section: Mmms 201mentioning

confidence: 99%

Multi-objective optimization to specify optimal selective laser melting process parameters for SS316 L powder

Prasanth Kumar,

Boggarapu,

Narayana Murty

2023

MMMS

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“…Numerical simulation is one of the modern tools for predicting welding stresses and distortion. The technical literature reports studies on the use of various programs, such as SYSWELD [ 11 , 12 , 13 , 14 , 15 ], ANSYS [ 16 , 17 , 18 ], ABAQUS [ 19 , 20 ], or AUTODESK CFD [ 21 ], for modelling welding stress and distortion distributions.…”

Section: Introductionmentioning

confidence: 99%

Study of the TIG Welding Process of Thin-Walled Components Made of 17-4 PH Steel in the Aspect of Weld Distortion Distribution

Mróz,

Kucel,

Rąb

et al. 2023

Materials

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This article presents the results of a study on the distribution of weld distortion in thin-walled components made of 17-4 PH steel, resulting from TIG (Tungsten Inert Gas) welding. Both manual and automatic welding processes were examined. Physical simulation of the automated welding process was conducted on a custom-built welding fixture. Analysis of weld distortion in thin-walled components made of 17-4 PH steel was based on the results of measurements of transverse shrinkage and displacement angle values. These measurements were taken on thin-walled parts before and after the welding process using a coordinate measuring machine (CMM). To determine the effect of manual and automated welding processes on the microstructure of the welded joint area, metallographic tests and hardness measurements were performed. The microstructure was analyzed using a scanning electron microscope (SEM). An analysis of the chemical composition of selected welded joint zones was also conducted. These tests were performed using an optical emission spectrometer (OES). According to the results, the use of automated welding and special fixtures for manufacturing thin-walled aircraft engine components made of 17-4 PH steel reduces the propensity of these components for distortion due to the effects of the thermal cycle of the welding process. This conclusion is supported by the results of the observation of the microstructure and analysis of the chemical composition of the various zones of the welded joint area.

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“…A systematic popular statistical approach, namely, the Taguchi method 20 considers an orthogonal array (OA) and recommends few tests for generating information on performance indicators (PIs) to all possible combinations of the levels of input variables or to the full factorial design of experiments (DOE). This approach minimizes the expenditure as well as time-consumption of trial test runs and obtains solutions for many engineering optimization problems, such as minimization on the introduction of damages in composites due to drilling, [21][22][23][24] rigid body dynamic separation process during the flights of space vehicles, [25][26][27] heat exchanger performance, 28 planetary gears design, 29,30 welding [31][32][33][34][35][36] and machining processes, [37][38][39][40][41][42][43][44][45] and fuel engine performance. [46][47][48][49] Kumar et al 50 performed experiments to investigate the performance of HP considering three input variables (such as heat input [A], inclination angle [B], and flow rate [C]) for the three PIs: efficiency η ( ), thermal resistance (THR), and overall heat transfer coefficient (OHTC).…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Multiobjective optimization for the optimal heat pipe working parameters based on Taguchi's design of experiments

2021

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A heat pipe (HP) is a device transferring large quantities of heat through a small area of the cross‐section with very small deviations in temperature. The thermal impedance of HP is lower while thermal conductance is higher. HPs are designed for controlling temperature, amplification of heat flux, and diminution. HPs are being used in the cooling of aircraft and electronics, solar energy, systems of heat recovery, and nuclear reactors. Complex mathematical formulation demands experimentation to acquire the physical phenomena. Performing experiments is a tedious task with increasing the working parameters and their assigned levels. In such situations, a systematic statistical approach (viz., the Taguchi method) has to be adopted to minimize the number of experiments and to provide the information for the full factorial design of experiments. This paper adopts the modified Taguchi method and applies a simple and reliable multiobjective optimization concept to determine the optimal HP working parameters (viz., heat input, inclination angle, and flow rate). In the optimization process, efficiency, thermal resistance, and overall heat transfer coefficient are the performance indicators (PIs). Empirical relations are developed and validated for the PIs in terms of the HP working parameters. The recommended Taguchi's orthogonal array to perform a few tests may not have the set of optimal working parameters. Additional tests are to be performed to confirm the estimates of the PIs for the optimal working parameters. Confirmation test results in the present study indicate close‐to/within the estimated range.

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Incorporation of Taguchi approach with CFD simulations on laser welding of spacer grid fuel rod assembly

Cited by 18 publications

References 36 publications

Multi-objective optimization to specify optimal selective laser melting process parameters for SS316 L powder

Multi-objective optimization to specify optimal selective laser melting process parameters for SS316 L powder

Study of the TIG Welding Process of Thin-Walled Components Made of 17-4 PH Steel in the Aspect of Weld Distortion Distribution

Multiobjective optimization for the optimal heat pipe working parameters based on Taguchi's design of experiments

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