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Multi objective Optimization of TIG welding AA6061 alloy using response surface methodology (RSM)
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Multi objective Optimization of TIG welding AA6061 alloy using response surface methodology (RSM)
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 12 | Dec 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 622 Multi objective Optimization of TIG welding AA6061 alloy using response surface methodology (RSM) Tadak Singh Kirade 1, Purushottam Sahu2 1Research Scholar BM College of Technology, Indore RGPV, BHOPAL 2Professor BM College of Technology, Indore RGPV, BHOPAL ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - This research paper discusses the experimental and numerical results of AA6061 TIG welding. The purpose of this research is to determine the best process parameters for GTAW of Argon, which is used as an inert gasinthealuminium alloy AA6061. The Taguchi method was used to optimize TIG welding process characteristics such as gas flow rate, welding current, and welding speed for connecting AA6061 plates. The Taguchi technique is used to obtain the Optimization parameters of Welding with tungsten inert gas on 6061 aluminium alloy. After examining the influence of various components with ANOVA and regression analysis, theTaguchi technique was used to find a desirable combination. Key Words: Hybrid laser-TIG welding Response surface methodology (RSM) Desirability approach, aluminium alloy AA6061, welding current, gas flow rate 1. INTRODUCTION The general principle TIG (tungsten inert gas) welding, also known as GTA (gas tungsten arc) in the United States and WIG (Wolfram inert gas) in Germany, is a welding process used to produce high quality materials of varioustypesUsed for welding, specifically, stainless steel, titanium and aluminium. 1.2 Equipment ● AC / DC Power Source ● TIG Torch ● Work Return Welding Lead ● Shielding gas supply line, (normally from a cylinder) ● Foot Control Unit (common option) Welding is the process of joining metalstogether, either with or without filler, to form coal's essence. Welding is a method of permanently joining materials.Shipbuilding,autos,andoil and gas are just a few of the industries that employ it. Arc welding is a process that involves creating an arc between the electrode and the workpiece,whichwarmsandmeltsthe metal. Electrodes can be consumable or non-consumable. Flux is used to protect weld metal fromenvironmental gases. The procedure can be carried either automatically or by hand. In the shipbuilding business, arc welding, which was pioneered in the nineteenth century, became commercially vital during WWII. It's still utilised in the manufacturing of steel pipelines and automobiles today. [2] Figure 1.1 Metal arc welding with a consumable electrode shield. The most popular, dependableandcost-effective weldingtechnologyis shielded arc welding, often known as manual arc welding. The consumable electrode utilised in this application is compatible with flux-coatedweldedsteel.Anelectriccurrent is utilised to strike an arc when the electrode is scratched along the workpiece. Figure 1.1 Classification of fusion welding processes.[46] Figure 1.2 Shielded metal arc welding process [46]
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 12 | Dec 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 623 Welding is a permanent joining process that uses heat, pressure, and filler materials to connect two or more materials, typically metals or thermoplastics.Tungsteninert gas welding is an electric arc welding method that uses non- consumable tungsten electrodes to create an arc between the electrode tip and the work piece. To prevent contamination of the weld with air, inert gases (argon, helium, etc.) are used. A mixture of any two of the gases described above is often used. TIG welding is one of the most flexible welding methods availabletoday,capableofconnectingtoalmost any metal or metal alloy. This welding method is popular because of its inherent benefits, such as high-quality and better welds, less deformation, a smaller heat-affected zone, and the absence of slag or spatter. TIG welding is widely used in industrial industries such as automobiles, airplanes, nuclear power plants, food processing plants, precision manufacturing plants and maintenance and repair work. [45]
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 12 | Dec 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 624 2. RESPONSE SURFACE METHODOLOGY OF EXPERIMENT Fig. 5.1 Optimization results of impact strength by RSM 3. Confirmation test The optimization results obtained have been validated by performing confirmatory experiments. Table 6 represents the results of confirmatory tests that are conducted in optimal conditions. It is seen from the table that the error in terms of percentage between the estimated and experimental results is very small and is less than 1%. This indicates that the optimized TIG welding process parameters higher NTS and UTS of 316L stainless steel can be obtained. Three fresh experiments are conducted for confirmation of models Eqs. (3) And (4), with achieved optimal values of cutting parameters. The average of measured values for surface roughness and kerf taper angle are tabulated in Table 6. The accuracy of the models isanalyzed on the basis percentage error. These errors are found to be 1.18 and 2.24% for surface roughness and kerf taper angle, respectively. It is possibly due to some vibrations during machining which affectsthemeasurement techniques. Since the error is less than10%, it is evidently proved that thereisa goodagreementbetween experimental and predicted values [38]. Table 5.1Multi-objective optimization results Fig. 5.2The effect of the process parameters on the Impact strength :( a) welding current and gas flow rate (b) Welding speed and welding current (c) gas flow rate r and welding speed. Fig. 5.3 Impact power contour plot (A) welding current and gas flow rate) (B) and weldingspeedandweldingcurrent (C) gas flow rate and welding speed Optimal Control Parameters Level Optimal Level Experimental Predicted (RSM) Error (%) Welding Current (A) A A4 B2 C4 2.251 2.1737 5.3 Gas flow rate (L/min) B Welding Speed (mm/s) C
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 12 | Dec 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 625 Figure 6-8 shows the limits of impact strength (A) against welding current (L / min), welding speed (mm / s) against gas flow rate (L / min), and welding speed (mm / s) (A) against the contour band welding current shown in (a). As shown in fig. 6, the impact strength is greater when the current is 190 A and the gas flow rate is 10 L/min.According to Fig.7, maximum impact strength is obtained at high welding speeds (54 mm/s) with a gas flow rate of 13 L/min. 4.CONCLUSION AND FUTURE APPLICATIONS 1. Response surface methodology (RSM) has been found to be extremely useful in the current study's optimization process. In this case, the predicted value from the models is very close to the experimental value. 2. The most important welding parameter affectingultimate tensile strength is gas flow rate, which is followed by welding current and welding speeds. 3. The most important factor influencing percentage elongation is welding current, with gas flow rate coming in second, followed by welding speed. 5. Impact strength ANOVA result (J). It is discovered that the most significant influence on impact strength is the Gas flow rate (L/min) (P=0.393) (32.62%), followed by Welding Speed (mm/s) (P=0.859) (6.90%) and the least significant influence is the Welding Current (A) (P=0.900) (5.22%). Welding current is an insignificantfactor forimpactstrength in the current study. 6. According to the ANOVA analysis, gas flow rateisthemost important factor influencing the impact strength of TIG welded AA6061 joints, followed by welding speed. REFERENCES: [1] NabenduGhosh et.al. Parametric Optimization of Gas Metal Arc Welding Process by using Taguchi method on Ferritic Stainless Steel AISI409. Elsevier, Materials Today: Proceedings 4 (2017) pg.2213–2221 [2] BhrudinHrinjica et.al.Welded Joint Tensile Strength Testing Of New And Used Material. 16th International Research/Expert Conference, TMT 2012, Dubai,UAE, 10-12 September 2012, pg 87-90 [3] Amit Pal. Mig Welding Parametric Optimization Using Taguchi’s Orthogonal Array And Analysis Of Variance. International Journal Of Research Review In Engineering Science & Technology, Volume-4, Issue-1, April-2015, pg.211-217 [4] VivekSaxena et.al. Optimization Of MIG Welding Parameters On Tensile Strength Of Aluminium Alloy By Taguchi Approach. International journal of Engg. [5] M. Ragavendran, N. Chandrasekhar, R. Ravikumar, R. Saxena, M. Vasudevan, A. K. Bhaduri. Optimization of hybrid laser - TIG welding of 316LN steel using response surface methodology (RSM).Optics and Lasers in Engineering 2017 (94), 27 – 36. [6] Dinesh Mohan Arya, Vedansh Chaturvedi, JyotiVimal (2016), Parametric optimization of MIG process parameters using Taguchi and Grey Taguchi analysis. International Journal of Research in Engineering and Applied Sciences, 3(6), 1–17. [7] NabenduGhosh,PradipKumarPal,GoutamNandi(2016), Parametric optimization of MIG welding on 316L austenitic stainless steel by Grey-based Taguchi method. Procedia Technology, 25, 1038–1048. [8] Doniavi A., Hosseini A., Ranjbary G. (2016), Prediction and optimization of mechanical properties of St52 in gas metal arc weld using response surface methodology and ANOVA, International Journal ofEngineeringTransactionsC: Aspects, 29(9), 1307–1313. [9] AbhishekPrakash, Raj Kumar Bag, PapinOhdar, Siva SankarRaju (2016), Parametric optimization of metal inert gas welding by using Taguchi approach. IJRET, 5(2), 176– 181.
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