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Summary

This study optimized color consistency in material processing using speed, temperature, and feed rate. The Box-Behnken design (BBD) offered superior results over the three-level full-factorial design (3LFFD) for process optimization.

Keywords:

3LFFD and BBD interaction for processing parameters microscopic characterization optimization polycarbonate regression models simulation

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Area of Science:

Materials Science and Engineering
Process Optimization
Color Science

Background:

Improving color accuracy and simulation models requires understanding process characteristics.
Previous research has focused on various processing factors to enhance material properties.
Optimizing uniform processing settings is crucial for consistent product quality.

Purpose of the Study:

To evaluate the impact of processing factors (speed, temperature, feed rate) on color parameters.
To compare the effectiveness of three-level full-factorial design (3LFFD) and Box-Behnken design (BBD) for process optimization.
To determine optimal processing settings for minimal color variance (dE*) and high desirability.

Main Methods:

Experimental approach to optimize process parameters while holding other variables constant.
Utilized Design Expert software for statistical and numerical optimization models.
Employed scanning electron microscopy (SEM) and micro-CT (MCT) for pigment dispersion analysis.

Main Results:

Processing parameters significantly affected color parameters (dL*, da*, db*) and specific mechanical energy (SME).
Increased feed rate led to a decrease in SME.
Box-Behnken design (BBD) achieved a minimum deviation of 0.26 and 87% desirability, outperforming 3LFFD (0.25 dE*, 77% desirability).

Conclusions:

Processing parameters significantly impact output quality, reducing variation and improving color consistency.
Box-Behnken design (BBD) is the preferred method for process optimization due to superior performance.
Optimized parameters promote sustainable production by minimizing waste.