Integrating Multi-Criteria Decision-Making and the Taguchi Method for High-Performance Material Selection in Rigid Flange Coupling Systems

Rigid flange couplings are essential components in mechanical power transmission systems, providing high torque transfer efficiency and structural integrity. The selection of optimal material combinations for these couplings is critical to ensuring durability, mechanical performance, and cost-effectiveness. This study presents a Multi-Criteria Decision-Making (MCDM) approach integrated with the Taguchi method and Finite Element Analysis (FEA) for systematic material selection and performance optimization. The research methodology involved determining coupling dimensions through manual calculations, developing 3D models in SolidWorks, and performing FEA simulations under predefined boundary conditions. The Taguchi L9 orthogonal array was employed to identify the best-performing material combinations based on multiple performance criteria, including tensile strength, shear strength, compressive strength, fatigue resistance, density, cost, and manufacturability. Statistical validation techniques such as Signal-to-Noise (S/N) ratio analysis were applied to ensure the reliability of results and predictive accuracy. Key findings indicate that integrating MCDM with the Taguchi method significantly enhances decision-making by balancing mechanical performance and economic feasibility. The optimized material selection improves equivalent stress distribution, shear stress resistance, total deformation, and equivalent elastic strain characteristics. This study bridges existing research gaps by offering a comprehensive, statistically validated, and experimentally optimized framework, benefiting engineers and industries involved in power transmission applications.