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Materials Today: Proceedings 5 (2018) 4748–4760 www.materialstoday.com/proceedings

ICMPC 2017

Multi-Response Optimization of Al2024/red mud MMC using

Hybrid Taguchi-GRA-Entropy Optimization Technique
Amit Sharmaa*, R.M.Belokarb, Sanjeev Kumarc
a
Ph.D Research Scholar, PEC University of Technology, Sector-12, Chandigarh-160012, India
b
Associate Professor, PEC University of Technology, Sector-12, Chandigarh-160012, India
c
Professor, PEC University of Technology, Sector-12, Chandigarh-160012, India

Abstract

In this paper multi-response optimization of the stir casting process has been carried using the hybrid Taguchi-GRA-Entropy
methodology. Al2024/red mud composite is prepared with the help of two-step stir casting process under the influence of argon
gas. Taguchi’s design of experiment is utilized for conducting the experiments. The process parameters under investigation are
reinforcement percentage, grain size and blade angle which are varied at three levels and their effect on the response variables
such as tensile strength and microhardness are studied. Grey relational analysis is used to derive the grey relational coefficients
and Entropy method is used to establish the weights of the individual quality characteristics. Grey relational grades are calculated
which act as a single response to the multi-response optimization problem which are analyzed using the Taguchi method in order
to identify the optimum conditions of the process parameters. Using ANOVA contribution of process parameters on the grey
relational grades are evaluated. Confirmatory experiments are performed which showcases that the proposed hybrid methodology
can be successfully applied for enhancing the performance of the stir casting process.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.

Keywords: Al2024; Red mud; Metal matrix composite; Taguchi method; Grey relational analysis; Entropy method

1. Introduction
Composites can be defined as the macroscopic combination of two or more distinct materials having different
properties that are combined together to achieve a desired balance of properties for a given range of applications
[1-3]. Various types of composites based on different matrix (metal, polymer and ceramics) have developed over a
period [4].

* Corresponding author. Tel.: +91-9041293477

E-mail address:amiter84@gmail.com

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.
 A.Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760 4749

Over the last few decades, metal matrix composites have been developed as a material system offering marvelous
blend of properties for imminent applications [5,6]. The principal benefits offered by these materials are their
enhanced mechanical properties, mainly in the areas of wear, strength and stiffness [7-9]. The principal matrix
materials are aluminium alloys, magnesium, titanium and its alloys [10-12]. Various types of materials are used as
reinforcement materials such as SiC, Al2O3, B4C, Zircon sand, fly ash and red mud [13-20]. Several methods can be
used to produce MMC’s out of which stir casting process is widely accepted by researchers all over the world
because of simple applicability of the process [21]. It is also effective because it uses the traditional metal
processing route and reduces the overall cost of production [22].Red mud is a major waste material obtained during
the production of aluminium from bauxite by the Bayer’s process [23]. Around one third of the bauxite ore is
dumped as red mud and is normally disposed in the form of dry mud. The storage and disposal of red mud has
caused serious environmental problems and danger to the persons living around them. Red mud particulate contains
oxides of silica, ferric, and alumina so it may be used as a reinforcement to fabricate the MMC’s [24]. It is available
free of cost and will provide an alternative to costly ceramic constituents available for the development of MMC.
Various optimization techniques are available for optimizing the responses out of which Taguchi method is the
most widely accepted method. The Taguchi technique is a powerful tool for acquiring the data in a controlled way
and in analyzing the effect of process variables on response variable [25]. The method has been applied by several
researchers in different fields for conducting and optimizing the process parameters. Tsao [26] used Taguchi method
for the analysis of drilling quality associated with core drill in drilling of composite material. L27 orthogonal array
and S/N ratio were employed to analyze the effect of drilling parameters such as diamond grit size, thickness, feed
rate and spindle speed on the response variables such as thrust force and surface roughness. Author concluded that
thickness and feed rate are found to be the most significant factors that contribute in increasing the overall
performance of the process. Tosun [27] used Taguchi method for the analysis of process parameters in drilling of
Al/SiCp MMC. Author concluded that Taguchi method was helpful in determining the optimum conditions which
resulted in achieving the desired surface roughness. Adalarasan et al. [28] used Taguchi method for the selection of
optimal machining parameters in pulsed CO2 laser cutting of Al6061/Al2O3 composite. Author concluded that the
methodology was helpful in establishing the optimum conditions of the process parameters in reduced number of
cutting trials and was found to be cost effective and time saving as well. The main problem that persists with
Taguchi method is that it can optimize single response whereas optimization of more than one response is desirable.
Grey theory has been effectively used in optimizing multiple responses. Several researchers have used this powerful
theory for the analysis of multi-response optimization problems. Pragadish and Kumar [29] used grey relational
analysis for the optimization of dry EDM process parameters. Tzeng et al. [30] used grey relational analysis for the
optimization of turning operation with multiple quality characteristics. Fung et al. [31] used grey relational analysis
to establish the optimal parameters of the injection moulding process. Yang et al. [32] used grey relational analysis
to optimize the dry machining parameters in end milling process. The main drawback of GRA is the establishment
of weighing values of the different quality characteristics. This problem can be rectified by the entropy method
which provide a systematic way for evaluate the weighing values of multiple quality characteristics. The method has
been used by several researchers and found it effective for establishing the weighing values of the multiple quality
characteristics [33-35].
In the context of above discussion the objective of this study is to analyze the developed Al2024/red mud MMC
which is fabricated using two-step stir casting process using the hybrid Taguchi-GRA-Entropy methodology for
simultaneously optimizing the multiple responses. Taguchi S/N ratio is used to evaluate the S/N ratio of the response
values using higher the better criterion. Data is normalized using the grey analysis which is further processed and
grey relational coefficients are calculated. Entropy method is used to evaluate the weighing component of individual
response and using these weights grey relational grades (GRG) are calculated. Taguchi method is applied on the
grey relational grades and the optimal levels of the process parameters are established. ANOVA is applied to find
the effect of individual process parameter on the grey relational grades. Confirmatory experiments are conducted to
validate the effectiveness of the hybrid optimization methodology.
2. Experimental work 2.1. Material
In this paper aluminium alloy 2024 is used as the matrix material as it exhibits remarkable properties for use in
applications requiring high strength to weight ratio, as well as good fatigue resistance. It is commonly used in the
4750 A. Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760

manufacture of aircraft structures, scientific instruments, veterinary and orthopaedic equipments. Red mud is used as
a reinforcement material as it contains alumina, iron oxide, titanium oxide along with some other minor constituents.
The elemental composition of Al2024 and red mud are given in Table 1 and Table 2 respectively.
Table 1. Aluminium Alloy 2024 composition

Conc. Cu Mg Si Fe Mn Zn Ti Cr Al
% 4.29 1.29 0.07 0.2 0.54 0.03 0.06 0.01 Rem.

Table 2. Red mud composition

Conc. Al2O3 Fe2O3 SiO2 TiO2 Na2O CaO LOI

% 17-19 35-36 7-9 14-16 5-6 3-5 10-12

2.2. Plan of investigation

The process parameters and their levels under investigation are shown in Table 3. Experiments are performed
using three parameters varied at three levels. Degrees of freedom (DOF) required for the design are six. The
orthogonal array which satisfies the required DOF is L9. The experiments are conducted using L9 OA which is
shown in Table 4.
Table 3. Process parameters and levels used in the experimentation

Levels
Process Parameters Units
1 2 3
Reinforcement % 5 10 15
Grain Size Microns 90 150 250
Blade Angle Degree 90 120 180

2.3. Description of experimental work

The MMC was manufactured using two-step stir casting process under the influence of argon gas. A known
quantity of aluminium alloy was fed in the muffle furnace using a graphite crucible and was melted at 700oC.
Temperature of the furnace was lowered to 650oC±5oC. Red mud of required wt% of particular grain size was first
preheated to 700oC for three hours to improve its wettability with the matrix material and was then fed into the melt
with the stirrer set at 700 rpm. Small amount of magnesium (1% by weight) was added in order to further enhance
the wettability of the reinforcement. The temperature of the furnace was again raised to 700oC and stirring was
continued for 5 minutes. The developed slurry was then poured into the prepared mild steel cylindrical mould. After
pouring is over the melt was allowed to cool and solidify in the mould. The same procedure was followed to prepare
other samples of different wt % of red mud ranging from 5-15% with grain size of 90-250 microns respectively
3. Methodology

3.1. Taguchi method

Taguchi’s parametric design approach offers a simple and systematic method to optimize design for performance,
quality and cost. Compared to the conventional approach of experimentation, this method reduces the number
of experiments drastically using specially designed orthogonal arrays to determine the optimal condition of
the process parameters [36]. Taguchi method uses a statistical measure of performance called the signal to noise
ratio (S/N ratio) to evaluate the optimal parameter settings. S/N ratio is the ratio of mean to standard deviation.
There are three types of S/N ratio namely higher the better, smaller the better and nominal the better [37]. In the
present research higher the better criterion is used for optimization process which is given below.
 A.Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760 4751

a) Higher the better

= −10 ∑ (1)

Where n is the number of replications & is the observed response value ( = 1,2,3, . . . . . , n)

b) Smaller the better

= −10 ∑ (2)

c) Nominal the better

= −10 (3)

Where, = ∑ ,
( )
= ∑

Table 4. Orthogonal Array (L9)

Process parameters
Trial No.
Reinforcement Grain Size Blade Angle
1 2 2 3
2 1 2 2
3 3 2 1
4 1 3 3
5 3 3 2
6 3 1 3
7 2 1 2
8 2 3 1
9 1 1 1

3.2. Grey Relational Analysis

Grey relational analysis (GRA) theory was first proposed by Professor J. Deng in 1989. GRA is a technique that
measures the correlation degree between the factors [38]. GRA is characterized by small data requirements and
multifactor analysis. It involves data pre-processing depending upon the criterion to be used. The optimization steps
are given below.

1. Calculate the normalized values of the respective responses from the S/N ratio

Normalization is a process of transforming the input data to acceptable values for further processing. It is very
important to normalize the original data before performing any further analysis of the using the GRA process. In the
present work normalization of the data is carried out using larger the better criterion. The normalization is done
using the equations given below:
4752 A. Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760

a) Larger the better

∗ ( ) ( )
( )= (4)
( ) ( )
b) Smaller the better
∗ ( ) ( )
( )= (5)
( ) ( )

c) Nominal the better

∗ | ( ) |
( )=1− (6)
( )

Where ∗ ( ) is the normalized value, max ( ) is the highest value of ( ), min ( ) is the lowest value of
( ) and is the target value.

2. Derive the grey relational co-efficient

Further, a grey relational coefficient is derived from the normalized values of tensile strength and microhardness
using the equation given below:

∆ ∆
( )= (7)
∆ ( ) ∆

Where, ( ) is the grey relational coefficient, = 1,2,3,4,5. . . . , & = 1,2,3,4,5, . . . . , ; and are the
number of trials and responses respectively.

∆ ( ): Deviation sequence,
∗
∆ ( ) = ‖ ∗( ) − ( )‖, (8)

∗
∆ = ‖ ∗( ) − ( )‖, (9)
∀ ∀

∗
∆ =∀ ‖ ∗( ) − ( ) ‖, (10)
∀
∗
Where, ∗ ( ) represents the reference sequence and ( ) represents the comparability sequence. represents the
identification coefficient, where [0,1].

3. Generate the grey relational grade (GRG)

GRG value is found by using Eq. (11) which is given below where is the grey relational grade value of the
respective trial.

= ∑ ( ) (11)

In actual scenarios the effect of individual factor on the response is not the same; so different weightage can be
given to different factors to derive the grey grades. Considering the weights the GRG can be found as

=∑ ( ) (12)

Where, ∑ = 1, the total sum of the weights should always be equal to 1, represents the weight value of
individual quality characteristics.
 A.Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760 4753

3.3. Entropy method

The concept of "entropy" was introduced by Claude E. Shannon in 1948. The entropy is a measure of the
uncertainty associated with a random variable of the expected information content of a certain message and the
uncertainty is represented by a discrete probability distribution [39]. In recent times, entropy method is used to
decide the weights in grey relational analysis. According to the definition proposed by Wen et al. [40], the mapping
function : [0,1] → [0,1] used in entropy should satisfy three conditions given below:

1. (0) = 0
2. ( ) = (1 − )
3. ( ) is monotonically increasing in the range of ∈ (0,0.5)

Thus the following function ( ) can be used as the mapping function in entropy measurement.

( )= + (1 − ) −1 (13)

The maximum value of this function occurs at x=0.5. In order to let the mapping result in the range of [0,1], Wen
et al. defined new entropy as

= .
∑ ( ) (14)

The steps of calculating the weighing component using the entropy method are given below:

1. Calculate D which is the sum of grey relational coefficient in all sequences and is defined as

=∑ ( ), = 1,2,3, … . . , (15)

2. Calculate the normalized coefficient

= . (16)
( )×

Where, m: number of experimental trials

3. Calculate the entropy (e ) of each quality characteristics

( )
= ∑ (17)

4. Calculate the sum of entropy

=∑ (18)

5. Calculate weight of each quality characteristics

( )
= × , = 1,2,3, … … , (19)
∑ ( )

4. Results and Discussion

In this paper simultaneous optimization of the quality characteristics have been performed using the hybrid
Taguchi-GRA-Entropy method. The procedural steps for simultaneously optimizing the multiple responses are
given below:
4754 A. Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760

1. Calculate S/N ratio of each quality characteristics.

2. Normalize the S/N ratios of all quality characteristics.
3. Calculate the grey relational coefficients using Eq. (7).
4. Calculate the weights corresponding to each quality characteristics using the entropy method.
5. By utilizing the weights calculate the grey relational grades (GRG) by using Eq. (12).
6. Statistically analyze the GRG using the Taguchi method and obtain the optimum levels of process parameters.
7. Perform ANOVA to identify the effect of each process parameter on the quality characteristics.
8. Conduct the confirmatory experiments to verify the claims.

The experiments are performed using L9 orthogonal array in random order and each experiment was repeated
three times. The average values of the experiments results are shown in Table 5 along with the calculated S/N ratios
using higher the better criterion.

Table 5. Experimental results of tensile strength and microhardness

Average values S/N ratio (dB)

S.No
Tensile Strength (MPa) Microhardness (HV) Tensile Strength Microhardness

1 152.62 72.67 43.67 37.23

2 149.39 74.07 43.48 37.39

3 182.92 78.63 45.24 37.91

4 124.73 66.87 41.91 36.50

5 166.09 75.40 44.08 37.55

6 172.39 78.57 44.73 37.90

7 162.33 75.10 44.20 37.51

8 148.48 70.47 43.43 36.96

9 155.51 73.40 43.83 37.31

After the S/N ratios of individual responses are calculated, next step is to normalize the data which is done using
Eq. (4). The normalized values of each quality characteristics are shown in Table 6.
Table 6. Normalized values of quality characteristics

Normalized values
S.No
Tensile Strength Microhardness

1 0.5285 0.5177
2 0.4715 0.6312
3 1.0000 1.0000
4 0.0000 0.0000
5 0.6517 0.7447
6 0.8468 0.9929
7 0.6877 0.7163
8 0.4565 0.3262

9 0.5766 0.5745
 A.Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760 4755

Further grey relational coefficients were calculated using Eq. (7) for each quality characteristics. Prior to finding
the grey relational coefficient the deviation sequence of the individual quality characteristics were evaluated using
Eq. (8) and are shown below:

∆ (1) = | ∗ (1) − ∗ (1)|

= |1.00 − 0.5285| = 0.4715

∆ (2) = | ∗ (2) − ∗ (2)|

= |1.00 − 0.5177| = 0.4823

Table 7. Deviation sequence of individual quality characteristics

Deviation Sequence
Run
Tensile Strength Microhardness
1 0.4715 0.4823
2 0.5285 0.3688
3 0.0000 0.0000
4 1.0000 1.0000
5 0.3483 0.2553
6 0.1532 0.0071
7 0.3123 0.2837
8 0.5435 0.6738
9 0.4234 0.4255

The results of deviation sequence of individual quality characteristics are shown in Table 7 and using the table
values ∆ and ∆ are expressed and are given below,

∆ = ∆ (1) = ∆ (2) = 0.00

∆ = ∆ (1) = ∆ (2) = 1.00

The value of (identification coefficient) in Eq. (6) is taken as 0.5 indicating equal weightage to both the quality
characteristics. Using the values derived above the grey relational coefficients was calculated and the results are
shown in Table 8.
Table 8. Grey relational coefficients of individual quality characteristics

Grey Relational Coefficient

Run
Tensile Strength Microhardness
1 0.5147 0.5090
2 0.4861 0.5755
3 1.0000 1.0000
4 0.3333 0.3333
5 0.5894 0.6620
6 0.7655 0.9860
7 0.6155 0.6380
8 0.4791 0.4260
9 0.5415 0.5402
4756 A. Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760

Now prior to calculating the grey relational grades, weights are to be found out for individual quality
characteristics using the entropy method. The value of (sum of grey relational coefficients) is found out using Eq.
(15) and is shown in Table 9. After calculating the value of the value of normalized coefficient (s) is found out
using Eq. (16) with m=9, and which comes out to be 0.1713. Further using Eq. (17) the entropy ( ) for each quality
characteristic is found and is shown in Table 10.

Table 9. Sum of individual grey relational coefficient

Grey Relational Coefficient

Tensile Strength Microhardness

5.3252 5.6701

Table 10. Entropy values of individual quality characteristics

Entropy ( )

Tensile Strength Microhardness

0.0400 0.0375
0.0380 0.0418
0.0690 0.0658
0.0270 0.0255
0.0450 0.0471
0.0560 0.0651
0.0467 0.0456
0.0376 0.0319

0.0418 0.0395

By using the entropy values from Table 10, the total entropy is calculated by using Eq. (18) and which comes out
to be 0.8011. Further using Eq. 19 the weights for the individual quality characteristics are calculated and are shown
in Table 11. Putting these weights in Eq. (12) the grey relational grades were calculated and are shown in Table 12.

Table 11. Derived values of weight for individual quality characteristics Table 12. Grey relational grade (GRG) values

S.No GRG
Weight ( )
1 0.5119
Tensile Strength Microhardness
2 0.5308
0.50 0.50
3 1.0000
4 0.3333
5 0.6257
6 0.8758
7 0.6268
8 0.4526
9 0.5408
 A.Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760 4757

The grey relational grade acts as a single index to the multi-response optimization problem and was analyzed
with the help of Taguchi method using higher the better criterion. The average values of the process parameters at
respective levels based on the grey relational grades are shown in Table 13.
Table 13. Average GRG values of the process parameters at respective levels

Response Table for Means

Level Reinforcement Grain Size Blade Angle
1 0.4685 0.6829 0.6639
2 0.5295 0.6811 0.5944
3 0.8359 0.47 0.5757
Delta 0.3673 0.2129 0.0882
Rank 1 2 3

Table 14. ANOVA analysis of the GRG values

Analysis of Variance for Means

Source DOF Sum of Squares Variance F-ratio Contribution (%)
Reinforcement 2 0.2325 0.1163 16.69 66.56
Grain Size 2 0.0899 0.0450 6.45 25.74
Blade Angle 2 0.0130 0.0065 0.93 3.71
Residual Error 2 0.0139 0.0070 3.99
Total 8 0.3493

Main Effects Plot for SN ratios

Data Means
Reinforcement Grain Size Blade Angle
-1

-2
Mean of SN ratios

-3

-4

-5

-6

-7
1 2 3 1 2 3 1 2 3

Signal-to-noise: Larger is better

Fig. 1. Effect of process parameters on the GRG

The effect of individual process parameter on the grey grade values are shown in Fig. 1. From the figure it is
observed that the optimal settings of process parameters are found to be A3, B1 and C1 which results in the
maximization of the GRG values. ANOVA results are provided in Table 14 which reveals that reinforcement
(66.56%) was having a major effect on the grey relational grade followed by grain size (25.74%). Blade angle
(9.48%) was having minor effect on the GRG.
4758 A. Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760

Next step is to calculate the mean and the confidence interval of individual quality characteristics using the
optimal settings. The expected mean (µ) at the optimal settings is calculated by using the following equations,

= + + −2 (20)

= + + −2 (21)

Where , are the mean values of the tensile strength and microhardness at their respective levels.
and is the overall mean values of tensile strength and microhardness.

Confidence interval (CI) is calculated with the help of the equation given below:

= ∝ (1, ) + (22)

Where ∝ (1, ) is the F-ratio at a significance level of α%, α is the risk, is the error degrees of freedom, is
the variance of error, is the effective number of replications and R is the number of confirmation tests.

= N/[1 + total DOF in the estimation of mean] (23)

Where, N: Total number of results,

Finally confirmatory experiments were conducted at the optimal process parameters setting (A3, B1 and C1). The
results of the confirmatory experiments at the optimal settings of process parameters for tensile strength and
microhardness are presented in Table 15. It can be seen that the average values of the response characteristics falls
well within the 95% confidence interval (CICE) of the optimal range of the tensile strength and microhardness.
Table 15. Results of confirmation experiment

Response Variable Optimum condition Average Values At 95% Confidence Interval

Tensile Strength 191.85 MPa 184.24< <194.40

A3B1C1
Microhardness 80.70 HV 79.00< <81.95

5. Conclusion

In the present work, hybrid combination of Taguchi-GRA-Entropy method has been employed to determine the
optimal parameter setting of the multiple responses for the fabrication of Al2024/red mud MMC using two-step stir
casting process. In order to investigate the effect of effect of process parameters namely reinforcement percentage,
grain size and blade angle on the tensile strength and microhardness L9 orthogonal array has been employed.
Taguchi method has been employed to evaluate the S/N ratios which are further processed using grey relational
analysis. Entropy method is used to derive the weights for the individual quality characteristics in order to find the
grey relational grades (GRG) which act a single response to the multi response optimization problem. The GRG
values were analyzed using Taguchi method and the optimum settings of the process parameters were found to be
A3, B1 and C1 where A represent reinforcement at level 3, B represent grain size at level 1 and C represent blade
angle at level 1. ANOVA was performed on the GRG and it was found that reinforcement was having major effect
on the GRG followed by grain size whereas blade angle was having minor effect on the GRG. Confirmatory
experiments were performed at the optimal settings and it was found that the average values of tensile strength and
microhardness falls within the 95% confidence interval. The proposed hybrid optimization methodology presented
in this research paper clearly demonstrates that the methodology can be successfully applied to multi-response
optimization problems.
 A.Sharma et al./ Materials Today: Proceedings 5 (2018) 4748–4760 4759

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