Integrated shape and manufacturing optimization of disk-cam profiles using Taguchi–GRA approach and MATLAB–ANSYS framework

Disk-cam mechanisms are widely used in mechanical systems where synchronized motion transmission is essential. However, the concurrent optimization of cam profile and its manufacturing parameters remains underexplored, leading to suboptimal production costs and compromised profile quality in industrial practice. This research presents a novel integrated methodology for minimizing the total production cost of disk-cam mechanisms by concurrently optimizing the cam profile shape and manufacturing parameters. The proposed approach combines the Taguchi method for experimental design with Grey Relational Analysis (GRA) for multi-objective decision-making. A total of sixteen experimental cases were generated using an L16 orthogonal array to investigate the influence of four control parameters: motion type, number of B-spline control points, tool type, and mathematical optimization method. Each case was solved using a MATLAB–ANSYS integrated framework that incorporates both shape and cost considerations into a nested optimization structure. The results demonstrate that carbide tooling and the Interior Point Method (IPM) yield the highest production cost reductions, while the number of B-spline control points most significantly influences cam area and structural stress. Production cost reductions of up to 67.9% were achieved, with Case 5 identified as the multi-objective optimum and Cases 1, 9, 11, and 16 as single-response optima. ANOVA confirmed that the mathematical optimization method exerted the greatest influence on the composite Grey Relational Grade. The proposed framework offers a practical and scalable tool for cost-effective, precision-driven cam profile design, with direct applicability in high-speed manufacturing environments such as automotive engine systems, textile machinery, and automated assembly lines.