This document summarizes a study on using simulated annealing algorithm to predict weld bead geometry in gas metal arc welding. Key points:
1. The study develops mathematical models using multiple regression to predict four dimensions of weld bead geometry based on welding process parameters.
2. Experiments are conducted using a central composite design with five levels and factors including current, welding speed, gun angle, contact tip distance, and pinch.
3. The developed models are checked for adequacy and significance. Bead geometry is then predicted again using a simulated annealing algorithm for comparison.
The document presents a study that aims to optimize welding variables and predict weld bead geometry in gas metal arc welding (GMAW) process. Experiments were conducted using a central composite design to study the relationship between input process parameters (current, speed, angle, distance, pinch) and output parameters (bead width, height, depth, dilution). Mathematical models were developed using regression analysis. A neural network was then used to predict welding outputs, and a simulated annealing algorithm was applied to optimize the process parameters to achieve optimum dilution.
Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
IJERD (www.ijerd.com) International Journal of Engineering Research and Devel...IJERD Editor
1) The study aims to optimize the shape of an aluminum billet to minimize forging load through finite element analysis.
2) An initial finite element model of the closed die forging process was created in ANSYS with the billet represented by finite elements.
3) The billet height-to-diameter ratio was identified as the design variable to be optimized, with the goal of minimizing forging load while limiting equivalent plastic strain to less than the fracture strain of 1.05.
IRJET-Optimization of Process Parameter in Hardfacing by Shield Metal Arc Wel...IRJET Journal
This document summarizes a study that optimized process parameters for hardfacing mild steel using shielded metal arc welding (SMAW). The researchers conducted experiments with three parameters - welding current, electrode type, and number of welding layers - at two levels each, using a Taguchi L8 orthogonal array. Microhardness tests on the welded specimens found that electrode type had the strongest influence on hardness, contributing 95% to total variation. The highest average microhardness of 813 HV was achieved with a current of 140A, 650 electrode, and two layers. Analysis of variance confirmed that electrode and number of layers significantly affected hardness, while current did not.
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
The document presents a study that aims to optimize welding variables and predict weld bead geometry in gas metal arc welding (GMAW) process. Experiments were conducted using a central composite design to study the relationship between input process parameters (current, speed, angle, distance, pinch) and output parameters (bead width, height, depth, dilution). Mathematical models were developed using regression analysis. A neural network was then used to predict welding outputs, and a simulated annealing algorithm was applied to optimize the process parameters to achieve optimum dilution.
Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
IJERD (www.ijerd.com) International Journal of Engineering Research and Devel...IJERD Editor
1) The study aims to optimize the shape of an aluminum billet to minimize forging load through finite element analysis.
2) An initial finite element model of the closed die forging process was created in ANSYS with the billet represented by finite elements.
3) The billet height-to-diameter ratio was identified as the design variable to be optimized, with the goal of minimizing forging load while limiting equivalent plastic strain to less than the fracture strain of 1.05.
IRJET-Optimization of Process Parameter in Hardfacing by Shield Metal Arc Wel...IRJET Journal
This document summarizes a study that optimized process parameters for hardfacing mild steel using shielded metal arc welding (SMAW). The researchers conducted experiments with three parameters - welding current, electrode type, and number of welding layers - at two levels each, using a Taguchi L8 orthogonal array. Microhardness tests on the welded specimens found that electrode type had the strongest influence on hardness, contributing 95% to total variation. The highest average microhardness of 813 HV was achieved with a current of 140A, 650 electrode, and two layers. Analysis of variance confirmed that electrode and number of layers significantly affected hardness, while current did not.
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
Effect of machining parameters on surface roughness for 6063 al tic (5 & 10 %...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IRJET- Examination of Hardness Values for Ti-6Al-4V Welded Specimens and Micr...IRJET Journal
This document examines the hardness values and microstructural characterization of welded Ti-6Al-4V specimens. Hardness tests were conducted on different zones of welded specimens with different weld bead shapes. The fusion zone and heat-affected zone showed higher hardness than the base metal. Tensile tests revealed that specimens failed at the weld with a yield strength of 820 MPa and ultimate tensile strength of 890 MPa. Fractured surfaces were analyzed using scanning electron microscopy to understand failure modes. SEM images showed ductile failure with dimples in the base metal and no cracks in the welded region.
of flux cored arc welding process parameters ond duplex stainless steel clad q...A X.S
This document summarizes an experimental study that analyzed the effects of flux cored arc welding (FCAW) process parameters on clad quality when duplex stainless steel is used to clad low carbon structural steel plates. Experiments were conducted using a central composite design with four welding parameters (current, speed, nozzle distance, angle) and responses (bead width, penetration, reinforcement, dilution). Mathematical models were developed to relate the parameters to the responses using multiple regression analysis. The models can help select welding parameters to achieve desired clad quality.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
This document summarizes a research paper that investigates the effect of process parameters on TIG welding of aluminum alloy 65032. The researchers used Response Surface Methodology to determine the optimal welding speed, current, and gas flow rate to maximize tensile strength and elongation. Central composite design was used to conduct experiments. Mathematical models were developed from the results to study the effect of parameters on strength and elongation. Optimization was performed to find the optimum welding conditions. Confirmation tests validated the optimum parameter settings.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
1) A finite element model was developed and validated to simulate chip formation and breakage during metal cutting of AISI 4130 steel. The model was validated by comparing predicted and measured cutting forces and chip thickness over a range of cutting conditions.
2) The model uses an adaptive remeshing technique and material model to capture the large deformations during chip formation. A stress-based failure criterion is used to predict chip breakage from tensile stresses induced during chip curling.
3) Predicted chip breakage was qualitatively and quantitatively compared to experimental results for two chip breaker geometries, showing good agreement between simulation and testing.
The document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
The document describes research to optimize metal inert gas (MIG) welding process parameters to control angular distortion, measured as deck height, during fabrication of earthmoving equipment. Experiments were conducted using a fractional factorial design to examine the effects of welding speed, current, and voltage on deck height. Response surface methodology was used to develop mathematical models relating the process parameters to deck height. Analysis of variance identified that current and the interaction of current and voltage significantly affected deck height. The models were validated and found to predict deck heights within acceptable limits.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Determination of Significant Process Parameter in Metal Inert Gas Welding of ...IJERA Editor
The aim of present study is to determine the most significant input parameter such as welding current, arc
voltage and root gap during the Metal Inert Gas Welding (MIG) of Mild Steel 1018 grade by Analysis of
Variance (ANOVA). The hardness and tensile strength of weld specimen are investigated in this study. The
selected three input parameters were varied at three levels. On the analogy, nine experiments were performed
based on L9 orthogonal array of Taguchi’s methodology, which consist three input parameters. Root gap has
greatest effect on tensile strength followed by welding current and arc voltage. Arc voltage has greatest effect on
hardness followed by root gap and welding current. Weld metal consists of fine grains of ferrite and pearlite.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
IRJET - Mathematical Modelling to Predict Bead Geometry and Shape Relationshi...IRJET Journal
This document presents a study that develops a mathematical model to predict bead geometry and shape relationships for MIG welded aluminum 1200 plates. The study uses design of experiments to investigate the effects of welding speed, voltage, and wire feed rate on weld width, height of reinforcement, and reinforcement form factor. 15 experiments were conducted according to a central composite face centered design. The results were analyzed using response surface methodology and ANOVA to develop and validate the mathematical model relating the input and response parameters.
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
IRJET - Mathematical Analysis of Angular Distortion on GTA Welded Hot Rolled ...IRJET Journal
This document presents a study analyzing the angular distortion that occurs during gas tungsten arc welding (GTAW) of hot rolled E250 grade low carbon steel plates. Experiments were conducted varying welding current, speed, and torch angle according to a full factorial design. Angular distortion measurements were obtained and used to develop a mathematical model relating distortion to the input parameters. The model was evaluated using ANOVA to check its adequacy in predicting angular distortion for this welding process and material.
The document discusses an experiment that investigated the effect of gas metal arc welding (GMAW) process parameters on tensile strength. 28 samples of AISI 3CR12 grade steel were welded using a central composite design matrix with variables of voltage, wire feed rate, welding speed, and gas flow rate. Tensile tests found that tensile strength increased with welding speed and gas flow rate, but decreased with increasing wire feed rate and voltage. Interaction plots showed that tensile strength increased with gas flow rate at constant wire feed rate and increased with welding speed at constant wire feed rate. The conclusion is that the welding input parameters influence tensile strength.
The document describes a study that developed an artificial neural network (ANN) model to predict surface roughness, cutting force, and temperature during machining of Nimonic-75 and Nicrofer C-263 super alloys. Experiments were conducted to collect input/output data on cutting speed, feed rate, depth of cut, surface roughness, cutting force, and temperature. The ANN model was trained on this data and could accurately model the complex relationships between cutting conditions and output parameters for process analysis and optimization.
Effect of machining parameters on surface roughness for 6063 al tic (5 & 10 %...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IRJET- Examination of Hardness Values for Ti-6Al-4V Welded Specimens and Micr...IRJET Journal
This document examines the hardness values and microstructural characterization of welded Ti-6Al-4V specimens. Hardness tests were conducted on different zones of welded specimens with different weld bead shapes. The fusion zone and heat-affected zone showed higher hardness than the base metal. Tensile tests revealed that specimens failed at the weld with a yield strength of 820 MPa and ultimate tensile strength of 890 MPa. Fractured surfaces were analyzed using scanning electron microscopy to understand failure modes. SEM images showed ductile failure with dimples in the base metal and no cracks in the welded region.
of flux cored arc welding process parameters ond duplex stainless steel clad q...A X.S
This document summarizes an experimental study that analyzed the effects of flux cored arc welding (FCAW) process parameters on clad quality when duplex stainless steel is used to clad low carbon structural steel plates. Experiments were conducted using a central composite design with four welding parameters (current, speed, nozzle distance, angle) and responses (bead width, penetration, reinforcement, dilution). Mathematical models were developed to relate the parameters to the responses using multiple regression analysis. The models can help select welding parameters to achieve desired clad quality.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
This document summarizes a research paper that investigates the effect of process parameters on TIG welding of aluminum alloy 65032. The researchers used Response Surface Methodology to determine the optimal welding speed, current, and gas flow rate to maximize tensile strength and elongation. Central composite design was used to conduct experiments. Mathematical models were developed from the results to study the effect of parameters on strength and elongation. Optimization was performed to find the optimum welding conditions. Confirmation tests validated the optimum parameter settings.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
1) A finite element model was developed and validated to simulate chip formation and breakage during metal cutting of AISI 4130 steel. The model was validated by comparing predicted and measured cutting forces and chip thickness over a range of cutting conditions.
2) The model uses an adaptive remeshing technique and material model to capture the large deformations during chip formation. A stress-based failure criterion is used to predict chip breakage from tensile stresses induced during chip curling.
3) Predicted chip breakage was qualitatively and quantitatively compared to experimental results for two chip breaker geometries, showing good agreement between simulation and testing.
The document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
The document describes research to optimize metal inert gas (MIG) welding process parameters to control angular distortion, measured as deck height, during fabrication of earthmoving equipment. Experiments were conducted using a fractional factorial design to examine the effects of welding speed, current, and voltage on deck height. Response surface methodology was used to develop mathematical models relating the process parameters to deck height. Analysis of variance identified that current and the interaction of current and voltage significantly affected deck height. The models were validated and found to predict deck heights within acceptable limits.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Determination of Significant Process Parameter in Metal Inert Gas Welding of ...IJERA Editor
The aim of present study is to determine the most significant input parameter such as welding current, arc
voltage and root gap during the Metal Inert Gas Welding (MIG) of Mild Steel 1018 grade by Analysis of
Variance (ANOVA). The hardness and tensile strength of weld specimen are investigated in this study. The
selected three input parameters were varied at three levels. On the analogy, nine experiments were performed
based on L9 orthogonal array of Taguchi’s methodology, which consist three input parameters. Root gap has
greatest effect on tensile strength followed by welding current and arc voltage. Arc voltage has greatest effect on
hardness followed by root gap and welding current. Weld metal consists of fine grains of ferrite and pearlite.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
IRJET - Mathematical Modelling to Predict Bead Geometry and Shape Relationshi...IRJET Journal
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This document summarizes a study on the influence of process parameters in machining hybrid aluminum metal matrix composites (HAMMCs) using wire cut electrical discharge machining (WEDM). HAMMCs of aluminum 7075 reinforced with silicon carbide and boron carbide were fabricated using stir casting. Experiments were conducted using WEDM to machine the composites. The effects of voltage, pulse on-time, pulse off-time, and current on material removal rate and surface roughness were analyzed. The results showed that material removal rate decreased as reinforcement weight fraction increased. Pulse on-time and off-time were important factors influencing material removal rate, with higher pulse on-time and lower off-time resulting
ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR...meijjournal
Wire electrical discharge machining (WEDM) is a non conventional machining process which is widely used in machining of conductive materials.The applications of WEDM are in automobiles, aero-space, medical instruments, tool and die industries. in the present study analysis of effect of various control factors like Ton,Toff,Sv,Ip,Wf,Wt on checking the cutting rate of S7 steel is studied by using wire cut EDM and one factor time approach.S7 steels contain less carbon and higher toughness than the high carbon types that are more wear resistant. Shock resistant steels are used where heavy cutting or forming operations is required and chipping or breakage of high-carbon wear-resistant steels is a problem. The other big advantage of this study is to select the range of significant control factors for final experimentation.
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distance have been found to be respectively: 60.8%, 9.86%,
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26v, 475A at a trolley speed of 0.25 m/min and NPD of 16 mm.
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Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
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important aspect during electrical discharge machining (EDM). In this investigation an attempt has been made to assess the factors influencing electrode wear rate on the machining of AISI 304 SS. Design of experiments (full factorial design) concept has been used for experimentation. The machining experiments were conducted on a die sinking EDM machine using two levels of factors.
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This document summarizes a study that used Response Surface Methodology (RSM) to develop mathematical models relating submerged arc welding process parameters to weld bead geometry outcomes. Specifically:
1. Experiments were conducted varying voltage, current, welding speed, and nozzle-to-plate distance to measure their effects on weld reinforcement and width.
2. Regression analysis was used to develop models showing the relationship between input parameters and outputs. Voltage, current, and distance significantly affected reinforcement while speed and distance affected width.
3. Optimization analysis identified the parameter combinations (32 volts, 340 amps, 25mm distance for reinforcement; 20 volts, 32 amps for width) that produced the desired bead
Study of mechanical properties in mild steel using metal inert gas weldingeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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This document analyzes the optimization of process parameters for wire electrical discharge machining (WEDM) of stainless steel 316L. It conducts experiments using different controllable factors like discharge current, pulse on/off time, and arc gap. Taguchi design of experiments is used to optimize for maximum material removal rate. Experiments are conducted using a copper tool on 316L stainless steel workpieces. The results are analyzed to determine the optimum parameter levels for achieving higher material removal rate and better surface finish quality during WEDM of 316L stainless steel.
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Abstract The effect of various welding process parameters on the weldability of Mild Steel specimens of grade EN-3A having dimensions 150mm× 100mm× 6 mm, welded by metal inert gas welding were investigated. The welding current, arc voltage, welding speed, are chosen as welding parameters. The depth of penetrations were measured for each specimen after the welding operation is done on closed butt joint and the effects of welding speed, current, voltage parameters on depth of penetration were investigated. Index Terms: Mild Steel (EN-3A), metal inert gas welding, welding current, arc voltage and welding speed.
Multi-Objective Optimization of EDM process parameters using Taguchi-Grey Rel...IRJET Journal
This document presents a study that uses Taguchi-Grey Relational Analysis to optimize the EDM process parameters for aluminum work material with a copper electrode. The objectives are to maximize the material removal rate and minimize the tool wear rate and surface roughness. Experiments are conducted with four machining parameters (discharge current, pulse on time, flushing pressure, and polarity) each at two levels. Response data is analyzed using Grey Relational Analysis to determine the optimal parameter combination and ranking. The optimal levels found are discharge current of 16A, pulse on time of 1010 μs, flushing pressure of 5kgf/cm2, and normal polarity. Analysis of variance indicates that discharge current has the most significant influence on the output responses
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
1. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
Prediction and Control of Weld Bead Geometry in Gas Metal Arc
Welding Process Using Simulated Annealing Algorithm
1,
P, Sreeraj, 2,T, Kannan , 3,Subhasis Maji
1,
Department of Mechanical Engineering, Valia Koonambaikulathamma College of
Engineering Technology, Kerala, 692574 India
2,
Principal, SVS College of Eng ineering,Coimbatore,Tamilnadu,642109 India .
3,
Professor, Depart ment of Mechanical Eng ineering IGNOU, Delhi, 110068, India.
Abstract
In order to automate a welding process, which is a present trend in fab rication industry, it is necessary to have a
mathematical model that is to relate the process parameters. Because of high reliability, easiness in operation, high
penetration good surface finish and high productivity gas metal arc weld ing (GMAW) became a natural choice for fabrication
industries. This paper presents five level factorial techniques to predict four critical d imensions of bead geometry. The
developed models have been checked for adequacy and significance. The bead geometry is predicted again using Simulated
annealing Algorith m (SA).
Key Words: GMAW, Weld bead geometry, Multip le Regression, Mathematical models,
1. Introduction
Quality is a vital factor in today’s manufacturing world. Quality can be defined as the degree of customer
satisfaction. Quality of a product depends on how it performs in desired circu mstances. Quality is a very vital factor in the
field of weld ing. The quality of a weld depends on mechanical properties of the weld metal which in turn depends on
metallurg ical characteristics and chemical co mposition of the weld [1]. The mechanical and metallurg ical feature of weld
depends on bead geometry which is directly related to welding process parameters. In other wo rds quality of weld d epends on
in process parameters.GMA welding is a mu lti objective and mult ifactor metal fabrication technique. The process parameters
have a direct influence on bead geometry [2]. Fig 1 shows the clad bead geometry. Mechanical strength of clad metal is
highly influenced by the co mposition of metal but also by clad bead shape. This is an indicat ion of bead geometry. It main ly
depends on wire feed rate, welding speed, arc voltage etc. Therefore it is necessary to study the relationship between in
process parameters and bead parameters to study clad bead geometry. Th is paper highlights the study carried out to develop
mathematical and GA models to predict clad bead geometry, in stainless steel cladding deposited by GMAW [3].
Percentage dilution (D) = [B/ (A+B)] X 100
Figure 1: Clad bead geometry
2. Experimentation
The following machines and consumables were used for the purpose of conducting experiment.
1) A constant current gas metal arc welding machine (Invrtee V 350 – PRO advanced processor with 5 – 425 amps output
range)
2) Welding manipulator
3) Wire feeder (LF – 74 Model)
4) Filler material Stainless Steel wire of 1.2mm diameter (ER – 308 L).
5) Gas cylinder containing a mixtu re of 98% argon and 2% of o xygen.
6) Mild steel plate (grade IS – 2062)
Test plates of size 300 x 200 x 20mm were cut fro m mild steel plate of grade IS – 2062 and one of the surfaces is cleaned to
remove o xide and dirt before cladding. ER-308 L stainless steel wire of 1.2mm d iameter was used for depositing the clad
beads through the feeder. Argon gas at a constant flow rate of 16 litres per minute was used for shielding. The properties of
base metal and filler wire are shown in Tab le 1. The important and most difficult parameter found fro m trial run is wire feed
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2. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
rate. The wire feed rate is proportional to current. Wire feed rate must be greater than crit ical wire feed rate to achieve pulsed
metal transfer. The relationship found from trial run is shown in equation (1). The formu la derived is shown in Fig 2.
Wire feed rate = 0.96742857 *current + 79.1 --------------------- (1)
The selection of the welding electrode wire based on the matching the mechanical propert ies and physical characteristics of
the base metal, weld size and existing electrode inven tory [4]. A candidate material for cladding which has excellent
corrosion resistance and weld ability is stainless steel. These have chloride stress corrosion cracking resistance and strength
significantly greater than other materials. These have good surface appearance, good radiographic standard quality and
minimu m electrode wastage. Experimental design used for this study is shown in Fig 3 and importance steps are briefly
explained.
Table 1: Chemical Composition of B ase Metal and Filler Wire
Elements, Weight %
M aterials C SI Mn P S Al Cr Mo Ni
IS 2062 0.150 0.160 0.870 0.015 0.016 0.031 - - -
ER308L 0.03 0.57 1.76 0.021 1.008 - 19.52 0.75 10.02
Figure 2: Relationshi p between Current and Wire Feed Rate
3. Plan of Investigation
The research work is carried out in the following steps [5] .Identificat ion of factors, finding the limit of process
variables, development of design matrix, conducting experiments as per design matrix, record ing responses, development of
mathematical models, checking adequacy of developed models, and predicting the parameters.
3.1 Identification of Factors and Responses
The basic difference between weld ing and cladding is the percentage of dilution. The properties of the cladding is
the significantly in fluenced by dilution obtained. Hence control of dilution is impo rtant in cladding where a low dilution is
highly desirable. When dilution is quite lo w, the final deposit composition will be closer to that of filler material and hen ce
corrosion resistant properties of cladding will be great ly improved. The chosen factors have been selected on the basis to get
minimal dilution and optimal clad bead geometry [1]. These are wire feed rate (W), welding speed (S), weld ing gun angle
(T), contact tip to work to The following independently controllable process parameters were found to be affecting output
parameters distance (N) and pinch (Ac), The responses chosen were clad bead width (W), height of reinforcement (R), Depth
of Penetration. (P) and percentage of d ilution (D). Th e responses were chosen based on the impact of parameters on final
composite model.
3.2 Findi ng the limi ts of process vari ables
Working ranges of all selected factors are fixed by conducting trial run. This was carried out by varying one of
factors while keeping the rest of them as constant values. Working range of each process parameters was decided upon by
inspecting the bead for smooth appearance without any visible defects. The upper limit of given factor was coded as -2. The
coded value of intermediate values were calculated using the equation (2)
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3. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
= ---------------- (2)
Where Xi is the required coded value of parameter X is any value of parameter fro m X min – X max. Xmin is the lower limit
of parameters and Xmax is the upper limit parameters [4].
The chosen level of the parameters with their un its and notation are given in Table 2.
Table 2: Wel ding Parameters and their Levels
Parameters Factor Levels
Unit Notation -2 -1 0 1 2
Welding Current A 1 200 225 250 275 300
Welding Speed mm/min S 150 158 166 174 182
Contact tip to work distance mm N 10 14 18 22 26
Welding gun Angle Degree T 70 80 90 100 110
Pinch - Ac -10 -5 0 5 10
3.3 Devel opment of design matrix
Design matrix chosen to conduct the experiments was central co mposite rotatable design. The design matrix
comprises of full replication of 25 (= 32), Factorial designs. All weld ing parameters in the intermediate levels (o) Constitute
the central points and combination o f each welding parameters at either is highest value (+2) or lowest (-2) with other
parameters of intermediate levels (0) constitute star points. 32 experimental t rails were conducted that make the estimation of
linear quadratic and two way interactive effects of process parameters on clad geometry [5].
Figure 3: GMAW Circuit Di agram
Table 3: Design Matrix
Trial Number Design M atrix
I S N T Ac
1 -1 -1 -1 -1 1
2 1 -1 -1 -1 -1
3 -1 1 -1 -1 -1
4 1 1 -1 -1 1
5 -1 -1 1 -1 -1
6 1 -1 1 -1 1
7 -1 1 1 -1 1
8 1 1 1 -1 -1
9 -1 -1 -1 1 -1
10 1 -1 -1 1 1
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4. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
11 -1 1 -1 1 1
12 1 1 -1 1 -1
13 -1 -1 1 1 1
14 1 -1 1 1 -1
15 -1 1 1 1 -1
16 1 1 1 1 1
17 -2 0 0 0 0
18 2 0 0 0 0
19 0 -2 0 0 0
20 0 2 0 0 0
21 0 0 -2 0 0
22 0 0 2 0 0
23 0 0 0 -2 0
24 0 0 0 2 0
25 0 0 0 0 -2
26 0 0 0 0 2
27 0 0 0 0 0
28 0 0 0 0 0
29 0 0 0 0 0
30 0 0 0 0 0
31 0 0 0 0 0
32 0 0 0 0 0
I - Wel ding current; S - Wel ding s peed; N - Contact ti p to work distance; T - Wel ding gun angle; Ac – Pinch
3.4 Conducting experi ments as per design matri x
In this work Thirty two experimental run were allo wed for the estimation of linear quadratic and two -way interactive
effects of correspond each treat ment co mb ination of parameters on bead geo metry as shown Table 3 at rando m. At each run
settings for all parameters were d isturbed and reset for next deposit. This is very essential to introduce variability caused by
errors in experimental set up. The experiments were conducted at SVS College of Engineering, Coimbatore, 642109, India.
3.5 Recordi ng of Responses
For measuring the clad bead geo metry, the transverse section of each weld overlays was cut using band saw fro m
mid length. Position of the weld and end faces were machined and grinded. The specimen and faces were polished and etched
using a 5% nital solution to display bead dimensions. The clad bead profiles were t raced using a reflective type optical prof ile
projector at a magnification of X10, in M/s Roots Industries Ltd. Coimbatore. Then the bead dimension such as depth of
penetration height of reinforcement and clad bead width were measured [6]. The profiles traced using AUTO CAD software.
This is shown in Fig 4. Th is represents profile of the specimen (front side).The cladded specimen is shown in Fig. 5. The
measured clad bead dimensions and percentage of dilution is shown in Table 4.
Figure 4: Traced Profile of bead geometry
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6. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
C = Contact tip to Work distance (N) in mm
D = Welding gun angle (T) in degrees
E = Pinch (Ac)
The second order surface response model equals can be expressed as below
Y = β 0 + β 1 A + β 2 B + β 3 C + β 4 D + β 5 E + β 11 A2 + β22 B2 + β 33 C2 + β 44 D2 + β 55 E2 + β12 AB + β 13 AC + β 14 AD + β 15 AE +
β 23 BC + β 24 BD + β 25 BE + β 34 CD + β35 CE+ β 45 DE --------- (4)
Where, β 0 is the free term of the regression equation, the coefficient β 1 , β2 , β3 , β4 and β5 is are linear terms, the coefficients β 11 ,
β 22 , β33 , β44 and ß 55 quadratic terms, and the coefficients β 12 , β13 , β14 , β15 , etc are the interaction terms. The coefficients were
calculated by using Quality A merica six sig ma software (DOE – PC IV). After determining the coefficients, the mathemat ical
models were developed. The developed mathematical models are g iven as follo ws.
--------------------------------------------------------- (5)
---------------------------------------------------------- (6)
------------------------------------ (7)
------------------------------------------------ (8)
Clad Bead Wi dth (W), mm = 8.923 + 0.701A + 0.388B + 0.587C + 0.040D + 0.088E – 0.423A 2 – 0.291B2 – 0.338C2 –
0.219D2 – 0.171E2 + 0.205A B + 0.405AC + 0.105AD + 0.070A E–
0.134BC+0.225BD+0.098BE+0.26CD+0.086CE+0.012DE ----------------------- (9)
Depth of Penetration (P), mm = 2.735 + 0.098A – 0.032B + 0.389C – 0.032D – 0.008E – 0.124A 2 – 0.109B2 – 0.125C2 –
0.187D2 – 0.104E2 – 0.33AB + 0.001 AC + 0.075AD +
0.005 AE– 0.018BC+0.066BD+0.087BE+0.058CD+0.054CE– 0.036DE ----------------------- (10)
Height of Reinforcement (R), mm = 5.752 + 0.160A – 0.151B – 0.060C + 0.016D – 0.002E + 0.084A 2 + 0.037B2 –
0.0006C2 + 0.015D2 – 0.006E2 + 0.035A B + 0.018AC – 0.008AD – 0.048A E– 0.024BC–0.062BD–0.003BE+0.012CD–
0.092CE–0.095DE.------------------------(11) Percentage Dilution (D), % = 19.705 +
0.325A + 0.347B + 3.141C – 0.039D – 0.153E – 1.324A 2 – 0.923B2 – 1.012C2 – 1.371D2 – 0.872E2 – 0.200AB + 0.346 AC +
0.602 AD + 0.203A E+0.011BC+0.465BD+0.548BE+0.715CD+0.360CE+0.137DE ------------------------ (12)
Co-efficient of the above polynomial equation where calculated by reg ression as given by equations (5) to (8)
3.7 Checking the adequacy of the developed models
Analysis of variance (ANOVA) technique was used to test the adequacy of the model. As per this technique, if the F
– ratio values of the developed models do not exceed the standard tabulated values for a desired level of confidence (95%)
and the calculated R – ratio values of the developed model exceed the standard values for a desired level of confidence (95%)
then the models are said to be adequate within the confidence limit [10]. These conditions were satisfied for the developed
models. The values are shown in Table 5.
Table 5: Anal ysis of variance for Testing Adequacy of the Model
2 nd order
1 st Order terms Lack of fit Error terms Whether
Paramete terms F- R-
model is
r ratio ratio
adequate
SS DF SS DF SS DF SS DF
W 36.889 20 6.233 11 3.51 3 6 2.721 5 1.076 3.390 Adequate
P 7.810 20 0.404 11 0.142 6 0.261 5 0.454 7.472 Adequate
R 1.921 20 0.572 11 0.444 6 0.128 5 2.885 3.747 Adequate
506.07 21.73
D 20 11 6.289 6 15.45 5 0.339 8.189 Adequate
4 9
SS - Sum of squares; DF - Degree of freedom; F Ratio (6, 5, 0.5 ) = 3.40451; R Ratio (20, 5, 0.05) = 3.20665
4. The Prediction Function
The mathematical models furn ished above provide one to one relationships between process parameters and weld bead
geometry. They can be used in two ways;
||Issn 2250-3005(online)|| ||January| 2013 Page 218
7. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
1) Pred icting weld bead geometry based on in p u t p a ramet ers an d
2) Pred ict in g p ro cess parameters for a desired weld bead specification.
The later o ne is mo re p ract ical s in ce t he weld ing parameters are usually set based on desired bead geometry. For this
purpose, the set of non-linear equations must be solved simultaneously for all the process parameters. Evolutionary algorith ms
are powerful optimization techniques widely used for solving combinatorial problems. Nevertheless, other capabilit ies of these
techniques have rarely been explored. As a new and promising approach, one of these algorith ms, called SA , is implemented
for prediction purposes in this research.
To predict the process parameters based on a desired bead quality, we first define the prediction function as follow(13):
E= + ………………………………………………………..
(13)
Where:
are bead specifications namely penetration, reinforcement, width of weld bead and percentage of
dilution respectively which are given by Equations 9 to 12. In the same manner, we define as the targ et valu es
for the desired weld bead geometry.
The coefficients represent weighing importance of different parameters in the objective function. In the prediction process, the
purpose is to min imize this o b ject iv e fun ct io n . By d o in g so , th e p rocess parameters are calculated in such way that the
bead geometry parameters approach their desired values. A SA method is emp loyed to find the best weld ing variables with
respect to process specifications.
5. Simulated Annealing Algorithm
Simu lated annealing was originally inspired by formation of a crystal in s olids during cooling. As discovered by
long ago by Iron Age black s miths the slower cooling, the most perfect crystal is formed. By cooling co mplex physical
systems naturally converge towards state of minimal energy. The systems move randomly, but probability to stay in a
particular configuration depends directly on the energy of the system and on its temperature. Gibbs law stated as equation
(14).
P= ---------- (14)
Where E stands for energy k is the Bolt zmann constant and T is the temperature. The iterat ion of the simulated annealing
consists of randomly choosing a new solution in the neighbourhood of actual solution. If the fitness function of the new
solution is better than the fitness function of the current one the new solution is accepted as the new current solution. If the
fitness function is not improved the new solution will be retained with p robability shown in equation (15).
P= -------- (15)
Where f(y)-f(x), being the difference between new and old solutions.
In this study Simulated Annealing (SA) which utilizes stochastic optimizat ion is used for the optimizat ion of clad bead
geometry deposited by GMAW. The main advantage of using this stochastic algorithm is that global optimizat ion point can
be reached regardless of the initial starting point. Since the algorith m incorporates. The major advantage of SA is an abilit y to
avoid being trapped at a local optimu m point during optimization. The algorith m emp loys a random search accepting not only
the changes that improve the objective function but also the changes that deteriorate it.Fig.6 shows simu lated annealing
algorith m. [11]
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8. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
Figure. 6 Trad itional Simulated Annealing A lgorith ms
6 An Illustrative Example
In this section a numerical example is presented to illustrate the performance of proposed procedure and solution technique
[12]. The target values for desired weld bead geometry are given in Table 6.
Table 6 Target values for weld bead geometry.
Weld Bead Geometry Target Value
Pt , (mm) 2.49
Rt (mm) 5.83
Wt (mm) 7.99
D t (%) 12.59
Without lose of generality, all elements of the bead geometry are assumed to be of the same importance and therefore constants
al to a7 are set to unity [13].
The prediction function given in Equation 13 along wit h weld bead mo deling eq uat ions 9 to 12 are embedded into SA
algorithm. The parameters for the algorithm are set as follows and shown in Table 7:
Table 7. SA process parameters
Annealing Function Bolt zmann Annealing
Population size 30
Re annealing temperature 100
Initial Temperature 100
Data Type Double
The objective is to minimize the perdition function which is used as the fitness criterion in evaluation each generation of
solutions. The best values found by proposed SA for process parameters are presented in Table 8. By setting these parameters in
GMAW, the target weld bead geometry specificat ions may be achieved.
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9. I nternational Journal Of Computational Engineering Research (ijceronline.com) Vol. 3 Issue. 1
Table 8 Predicted values for process parameters.
Process parameters Predicted value by S A
Welding current (I) 242
Welding Speed (S) (mm/min) 161
Contact tip to work distance (N) mm (m/min) 16
Welding Gun Angle (T) Degree 88
Pinch(Ac) -10
The performance of the solution procedure was tested by substituting parameters values obtained by GA into the weld bead
models and comparing the results with the des ired valu es of bead geo met ry. The co mparison of the calculated and desired
values is shown in Table 9. The largest error is around 0.3 while most parameters deviate much less than 1% from their desired
values. The computational results show that GA can be used efficiently and with good accuracy as a prediction technique.
Table 9 Comparison between desired and predicted weld bead geometry values
Weld Bead Geometry Targets S AResults Error
Penetration 2.29 2.493 .203
Reinforcement 5.83 6.213 .383
Clad Bead Width 7.9 8.35 .45
Clad Bead Width 7.9 8.35 .45
7. Results and Discussions
1. A five level five factor fu ll factorial design matrix based on central co mposite rotatable design technique was used for
the mathematical development of model to predict clad bead geometry of austenitic stainless steel deposited by GMAW.
2. SA tool available in MATLA B 7 software was efficiently emp loyed for pred iction of clad bead geometry.
3. In cladding by a weld ing process clad bead geometry is very important for economising the material. Th is study
effectively used SA models to predict weld bead geometry.
4. In this study two models regression and SA system for prediction of bead geometry in GMAW welding process. In this
study it is proved that SA model pred iction is efficient and error is appro ximately equal to five percent.
8. Conclusions
Based on the above study it can be observed that the developed model can be used to predict clad bead geo metry
within the applied limits of process parameters. This method of predicting process parameters can be used to get minimu m
percentage of dilution. In this study regression and SA was used for achieving optimal clad bead dimensions. In the case of
any cladding process bead geometry plays an important role in determining the properties of the surface exposed to hostile
environments and reducing cost of manufacturing. In this approach the objective function aimed for predicting weld bead
geometry within the constrained limits.
Acknowledgement
The authors sincerely acknowledge the help and facilities extended to them by the department of mechanical
engineering SVS college of Eng ineering, Co imbatore, India .
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