This document describes a study that used response surface methodology (RSM) to develop mathematical models relating submerged arc welding process parameters to weld bead geometry characteristics. Researchers conducted experiments with varying levels of welding current, voltage, speed, and nozzle-to-plate distance. Regression analysis was used to develop models and optimize the parameters to achieve desired bead reinforcement and width. The optimal parameters found were a current of 337 amps, voltage of 32 volts, speed of 20 inches/minute, and distance of 25mm for maximum reinforcement of 2.30mm.
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.
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.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
The present paper is on the analysis of surface roughness characteristics Ra, Rq and Rz during the machining of
medium carbon steel EN19. The experiments have been done under dry environment by using a coated carbide
tool. For the optimization of process parameters Taguchi based Grey Relational Grade method was used.
Taguchi’s standard L9 Orthogonal Array was used for conducting the experiments. From the Grey analysis,
optimal parametric combination for multi-responses (Ra, Rq and Rz) was found at cutting speed: 225 mm/min,
feed: 0.05 mm/rev and depth of cut: 0.4 mm respectively. Analysis of variance (ANOVA) was used for analyse
the influence of process parameters on multi responses. From the analysis it is concluded that, speed has high
influence (F= 34.18, P= 0.025<0.05)>0.05). Regression models were developed for Ra, Rq and Rz, which are
very significant parameters from contact stiffness, fatigue strength and surface wear point of view. The models
prepared were highly significant because they have high coefficient of correlation values (R2 =0.992, 0.987 and
0.982 for Ra, Rq and Rz respectively). Hence, the models can be used for accurate prediction of surface
roughness characteristics.
A STUDY OF THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS USING RES...IAEME Publication
A series of experiments to determine the character of surface of the alloy steel have been conducted. The main objective of this work is to develop a holistic understanding of the effects of
feed rate, spindle speed, depth of cut and type of coolant on the surface roughness and to create a model for the conducted study. Such an understanding can provide sapience about the shortcomings of controlling the finish of machined surfaces when the process parameters are adjusted to obtain a certain surface finish. The model, which includes the effect of spindle speed, cutting feed rate and depth of cut, and any three variable interactions, predicted the surface roughness values.
EXPERIMENTAL STUDY OF TURNING OPERATION AND OPTIMIZATION OF MRR AND SURFACE R...AM Publications
In this research work turning operation is performed on AISI 1020 mild steel. Here we conducted experiments by taking Cutting Speed, Feed Rate & Depth of cut as process parameters and got the optimized value of MRR & SR. An L9 orthogonal array, the signal-to-noise (S/N) ratio are employed to the study the performance characteristics in the turning using WNMG332RP carbide insert with a nose radius of 0.8mm. Taguchi method is used to optimize surface roughness and material removal rate (MRR) during machining operation on CNC turning. The experimental result shows that on increasing depth of cut and feed the combined S/N ratio increases while on increasing cutting speed the combined S/N ratio decreases. It results that cutting speed is most significantly influences the Surface roughness followed by feed and in case of MRR, depth of cut is the most significant parameter followed by cutting speed .While the combination of both is most significantly affected by the depth of cut followed by the feed.
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
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
The present paper is on the analysis of surface roughness characteristics Ra, Rq and Rz during the machining of
medium carbon steel EN19. The experiments have been done under dry environment by using a coated carbide
tool. For the optimization of process parameters Taguchi based Grey Relational Grade method was used.
Taguchi’s standard L9 Orthogonal Array was used for conducting the experiments. From the Grey analysis,
optimal parametric combination for multi-responses (Ra, Rq and Rz) was found at cutting speed: 225 mm/min,
feed: 0.05 mm/rev and depth of cut: 0.4 mm respectively. Analysis of variance (ANOVA) was used for analyse
the influence of process parameters on multi responses. From the analysis it is concluded that, speed has high
influence (F= 34.18, P= 0.025<0.05)>0.05). Regression models were developed for Ra, Rq and Rz, which are
very significant parameters from contact stiffness, fatigue strength and surface wear point of view. The models
prepared were highly significant because they have high coefficient of correlation values (R2 =0.992, 0.987 and
0.982 for Ra, Rq and Rz respectively). Hence, the models can be used for accurate prediction of surface
roughness characteristics.
A STUDY OF THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS USING RES...IAEME Publication
A series of experiments to determine the character of surface of the alloy steel have been conducted. The main objective of this work is to develop a holistic understanding of the effects of
feed rate, spindle speed, depth of cut and type of coolant on the surface roughness and to create a model for the conducted study. Such an understanding can provide sapience about the shortcomings of controlling the finish of machined surfaces when the process parameters are adjusted to obtain a certain surface finish. The model, which includes the effect of spindle speed, cutting feed rate and depth of cut, and any three variable interactions, predicted the surface roughness values.
EXPERIMENTAL STUDY OF TURNING OPERATION AND OPTIMIZATION OF MRR AND SURFACE R...AM Publications
In this research work turning operation is performed on AISI 1020 mild steel. Here we conducted experiments by taking Cutting Speed, Feed Rate & Depth of cut as process parameters and got the optimized value of MRR & SR. An L9 orthogonal array, the signal-to-noise (S/N) ratio are employed to the study the performance characteristics in the turning using WNMG332RP carbide insert with a nose radius of 0.8mm. Taguchi method is used to optimize surface roughness and material removal rate (MRR) during machining operation on CNC turning. The experimental result shows that on increasing depth of cut and feed the combined S/N ratio increases while on increasing cutting speed the combined S/N ratio decreases. It results that cutting speed is most significantly influences the Surface roughness followed by feed and in case of MRR, depth of cut is the most significant parameter followed by cutting speed .While the combination of both is most significantly affected by the depth of cut followed by the feed.
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
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
To improve the corrosion resistant properties of carbon steel usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using Gas Metal Arc Welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, Artificial Neural Network (ANN) and Simulated Annealing Algorithm (SA) techniques were integrated labels as integrated ANN-SA to estimate optimal process parameters in GMAW to get optimum dilution.
Influence of process parameters on MRR in EDM of AISI D2 Steel: a RSM approachMohan Kumar Pradhan
Response Surface Methodology (RSM) is used to investigate the
effect of three controllable input variables namely: discharge current, pulse duration,
and pulse off time on material removal rate (MRR) in EDM process. To study the
proposed second-order polynomial model for MRR, a central composite design is
used to estimation the model coefficients of the three factors, which are believed to
influence the MRR in EDM process. Experiments were conducted on AISI D2 tool
steel with copper electrode. The response is modeled using RSM on the experimental
data. The significant coefficients are obtained by performing analysis of variance
(ANOVA) at 5% level of significance. It is found that discharge current, pulse duration,
and pulse off time and few of their interactions have significant effect on the MRR.
The model sufficiency is very satisfactory as the coefficient of determination (R2) is
found to be 97.6%.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
PROCESS PARAMETER OPTIMISATION IN WEDM OF HCHCR STEEL USING TAGUHI METHOD AND...IAEME Publication
Wire Electrical Discharge Machining (WEDM) is used as a valuable machining tool in the world of non-traditional machining due to various features which includes higher degree of accuracy, fine surface quality and good productivity. WEDM consists of large number of process parameters,
thus it is difficult to obtain a combination of optimum parameters which provides higher accuracy. Optimization of a single response is often carried out with the well known technique Taguchi method. This method results in the solution which gives optimum value of each response
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
This paper details the application of Taguchi
techniques to determine the optimal process parameters for
submerged arc welding (SAW).The planned experiment work is
conducted in the semiautomatic submerged arc welding machine
and signal to noise ratios have been computed .the contribution of
each factor has been validated by analysis of variance(ANOVA).
The results of the present investigation indicate that the welding
voltage is the most significant parameter that controls the bead
penetration as compared to other controlling parameters. The
contribution of voltage, current welding speed and nozzle-to-plate
distance have been found to be respectively: 60.8%, 9.86%,
3.54% and 13.8%. Optimum results have been obtained by using
26v, 475A at a trolley speed of 0.25 m/min and NPD of 16 mm.
Artificial Intelligence based optimization of weld bead geometry in laser wel...IJMER
This paper reports on a modeling and optimization of laser welding of aluminum-magnesium alloy thickness of 1.7mm. Regression analysis is used for modeling and Genetic algorithm is used for optimize the process parameters.The input values for the regression methods is taken according the Taguchi based orthogonal array. A software named Computer aided Robust Parameter Genetic Algorithm CARPGA has been developed in MATLAB 2013 which combine all of these methodologies. This software has been validated with some published paper.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
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• Remote control system for accessing CCR and allied system over serial or TCP.
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Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
2. International Journal of Mechanical Engineering Research and Development (IJMERD), ISSN
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[5]Optimum process parameters selection has been investigated by some significant studies
via establishing a mathematical model correlating welding parameters with quality
characteristics using different approaches [1]In this study, mathematical relations (empirical
equations) between submerged arc welding process parameters and weld bead characteristics
were constructed based upon the experimental data obtained by four parameters-two levels
factorial analysis. This paper deals withthe application of RSM in developing
mathematicalmodels and plotting contour graphs relating importantinput variables namely the
voltage(V), Current (I), the welding speed (S) andthe nozzle-to-plate distance (N), to the
reinforcement (R), the width (W)) of the weld bead in the SAW plates. These developed
models are very useful forengineers to predict the weld bead geometry for theproposed values
of input variables, to select an optimumcombination of input variables for the desiredweld
bead quality and to automise the SAW processthrough the development of a computer
program.The cross section of a typical weld bead is shown in fig.1
Fig .2 Experimental set-ups
II. EXPERIMENTAL PROCEDURE AND SET UP: In this research experiment is
mainly divided into six parts which is as follows.
a) IDENTIFYING PROCESS PARAMETERS:
The independently controllable process parameters were identified. They are welding current
(I), welding Speed (S), voltage (V), Nozzle to plate distance (N),It was found that wire feed
rate is directly proportional to the welding current.
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b) LIMITS OF THE PROCESS VARIABLES
Working range was decided by conducting trial runs and by inspecting the bead for
smooth appearance and the absence of any visible defects. For deciding the working range,
several trial welds were made. For determining the range of one variable, the other three
variables were kept constant during trial runs. A similar procedure was adopted for
determining the upper and lower limits for the welding speed and nozzle-to-plate distance.
Also, trial welds were made, keeping the values of all the parameters both at their minimum
and maximum values to verify quality of the weld bead, after determining the working range
of the process parameters, the upper limit was coded as +1 and -1.After determining the
working range of the process parameters ,the upper limit was coded as +1 and lower limit as -
1.The coded value of the intermediate levels were calculated from the relationship[4-9]
X୧ ൌ
2 x െ ሺX୫ୟ୶ X୫୧୬ሻ
ሺX୫ୟ୶ െ X୫୧୬ሻ
Where Xithe required coded value of a variable X; and X isis any value of the variable from
X min to X max. The selected process parameters with their limits, units and notations are
given
c) DEVELOPING THE DESIGN MATRIX
The selected design matrix, shown in Table 2, factorial design [4] consisting of 16
sets of coded conditions. Design matrix is blocked with their result to reduce irrelevant
source of variation. Response variables bead width and reinforcement are measured by using
scale and venire calliper
d)DEVELOPMENT OF MATHEMATICAL MODEL
The response function representing any of the weld bead dimensions can be expressed as [2-
9]
Y=F(S, V, I, N)
Where
Y is the response (Bead width, reinforcement)
I is the welding currents, amps
S is the welding speed, Inch/min.
N is the nozzle to plate distance, mm.
The relationship selected being a First degree response surface expressed as follows:
ܻ ൌ ܤ ܤଵܺଵ ܤଶܺଶ ڮ ܤܺ+ε
e) CHECKING THE ADEQUACY OF THE MODELS DEVELOPED
The adequacy of the models was tested using the analysis-of-variance technique
(ANOVA). As per this technique [2- 7]:
The estimated coefficients obtained above were used to construct models for the response
parameters. The adequacy of the models so developed was then tested by using the analysis
of variance technique (ANOVA). Using this technique, it was found that calculated F ratios
were larger than the tabulated values at a 95% confidence level; hence, the models are
considered to be adequate
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The adequacy of a fitted regression model are the coefficient of determination (R').
For the models developed, the calculated R2
and adjusted R2
values were
above 80% and 70%, respectively. These values indicate that the regression models are quite
adequate the validity of regression models developed were further tested by drawing scatter
diagrams. The observed values and predicted values of the responses are scattered close to
the 45 ° line, indicating an almost perfect fit of the developed empirical models.To improve
the reliability of result, experiments were planned on the basis of response surface
methodology (RSM) techniques for statistical design of experiment.
f) ExperimentalSet Up
The experiments were conducted at Rajarambapu Institute of Technology, Rajaramnagar,
Islampur. With the following experimental setup:
The equipment used: ESAB submerged arc-welding equipment.
Welding rod used: EH-14, 2. 4mm diameter.
Work piece: SA-516 Gr-70 steel plates of 500mm× 150mm×12mm size.
Type of joint: bead on joint with single Vbuttjoint with 0.5–1mm root gap.
Flux: ADOR make F7P2 granular type.
Regression Analysis
Regression analysis is used to establish the relation between the variables. In this
experiment the data was analyses by using minitab-15 software. Regression Equation
Reinforcement versus speed, voltage, current, distance is given below. Reinforcement=1.79-
0.0688 Speed-0.0813 Voltage+0.0812 Current+0.306Distance Whereas, Regression
Equation Width verses speed, voltage, current, distance is given as Width=18.60-
0.415Speed+0.380Voltage+0.0800Current-0.295distance.
III RESPONSE SURFACE METHODOLOGY
Response Surface Methodology (RSM) is a collection of statistical and mathematical
techniques useful for developing, improving, and optimizing processes [1]. The most
extensive applications of RSM are in the particular situations where several input variables
potentially influence some performance measure or quality characteristic of the process. Thus
performance measure or quality characteristic is called the response. The field of response
surface methodology consists of the experimental strategy for exploring the space of the
process or independent variables, empirical statistical modeling to develop an appropriate
approximating relationship between the yield and the process variables, and optimization
methods for finding the values of the process variables that produce desirable values of the
response
TABLE 1
Chemical composition of work piece (SA-516 Gr: 70)
Carbon Manganese Phosphorus
max4
Sulfur max4
Silicon
0.27 0.79-1.30 0.035 0.035 0.13-0.45
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TABLE: 2
Process control parameters and their limits
Variables Natural Value Coded Value
Speed 20 24 -1 +1
Voltage 32 40 -1 +1
Current 300 360 -1 +1
Distance 22 25 -1 +1
TABLE:3
Design matrix
Weld
conditions
Block I Weld
condition
Block II
Sp Vot Cu Dis Rein Wid Sp Vot Cu Dis Rein Wid
1 -1 -1 -1 -1 1.1 20.02 2 1 -1 -1 -1 1.3 17.66
4 1 1 -1 -1 1.2 18.42 5 -1 -1 1 -1 1.8 20
6 1 -1 1 -1 1.9 18.1 8 1 1 1 -1 1.2 19
7 -1 1 1 -1 1.5 18.6 9 -1 -1 -1 1 2.1 19.26
10 1 -1 -1 1 2 18.14 11 -1 1 -1 -1 1.6 18.54
11 -1 1 -1 1 1.9 18.20 12 1 1 -1 1 1.4 18.08
13 -1 -1 1 1 2.4 17.60 14 1 -1 1 1 2 18.06
16 1 1 1 1 2.1 19.20 15 -1 1 1 1 2.2 18.60
(Sp-Speed,Vol-Voltage,Cu-Current,Dis-Distance,Rein-Reinforcement,Wid-Width)
Regression Analysis:. Reinforcement=1.79-0.0688 Speed-0.0813 Voltage+0.0812
Current+0.306 Distance Whereas, Regression Equation Width verses speed, voltage, current,
distance is given as Width=18.60-0.415 Speed+0.380 Voltage+0.0800 Current-0.295distance.
TABLE 4
Analysis of variance table of block-1and block-2 for Response Variables
Response
variables
S R2
R2
adj Residual error Design
matrix
Reinforcement 0.122474 96.8%, 92.5 3 Block-1
Reinforcement 0.353742 95.1 88.6 3 Block-II
Width 0.3537 90.6 78.1 3 Block-1
Width 0.5711 75.4 42.7 3 Block-II
The Sequential Nature of the Response Surface Methodology
Most applications of RSM are sequential in nature
Phase 1: At first some ideas are generated concerning which factors or variables are likely to
be important in response surface study. It is usually called a screening experiment. The
objective of factor screening is to reduce the list of candidate variables to a relatively few so
that subsequent experiments will be more efficient and require fewer runs or tests. The
purpose of this phase is the identification of the important independent variables.
Phase 2: The experimenter’s objective is to determine if the current settings of the
independent variables result in a value of the response that is near the optimum. If the current
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settings or levels of the independent variables are not consistent with optimum performance,
then the experimenter must determine a set of adjustments to the process variables that will
move the process toward the optimum. This phase of RSM makes considerable use of the
first-order model and an optimization technique called the method of steepest
ascent(descent).
Result analysis by using minitab-15 software .
Table 5
Optimisation Table
Local Solution Predicted response desirability
Speed Voltage Current Distance Reinforcement width
20 32 337 25 2.30 - 0.999
20 32 300 22 - 18 0.999
Fig 3.Optimsation Plot for Bead width
Fig 4.Optimsation Plot for Reinforcement
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Optimisation Plot
The optimisation plot for width and reinforcement is as shown in the figure.
Optimsation plot show the variation of the response parameters for each factor i.e welding
current, voltage. Welding speed, difference between plate and nozzle. And its desirability is
0.9991.from the figure it is clear that above results are in linear regression or in straight line
and the optimal values are obtained in intermediate of the line. So from figure and analysis
data it is observed that the optimal value for reinforcement is 2.30 mm for that welding
current 337 amp, 32 voltage, speed 20 inch per minute and distance between plate and nozzle
is 25mm where as for width welding current 300 amp , 32 voltage, speed 20 inch per minute
and distance between plate and nozzle is 22mm
Conformation test
Once the optimal level of the welding parameters were selected, a conformation
experiment to verify the improvement of the response characteristics .based on response
surface analysis optimal welding parameters can then obtained. Using response surface
methodology optimal value for bead-width, bead-reinforcement .bead reinforcement is
increased from 1.1 to 2.30 mm where as bead width is decreased from 20 to 18 mm
thickness .from the above discussion it is clear that multiple response characteristics in the
saw process are optimised using new process setting
Results
The mathematical models furnished above can be used to predict the weld bead
geometry by substituting the values, in coded form, of the respective factors. The response
calculated from models for each set of coded welding variables are represented in graphical
from fig - also, by substituting the values of desired bead geometry , the values of the
control factors ,in coded form ,can be obtained. The main effect of the different process
variables on the weld bead dimensions predicted from the mathematical models using the
experimental observations.
Direct effect of the process parameter
Effect of voltage on reinforcement and bead width
As the voltage increases reinforcement decreases and Bead width increases. Because
as voltage increased reinforcement decreased, because voltage is directly to the length of the
current path between the welding wire and work-piece.so as the stick-out increases voltage is
also increases, due to that bead width is gradually increases and reinforcement is decreases.
Fig3 shows the direct effect of voltage on reinforcement. From figure it is clear that voltage
having negative effect on reinforcement.Whereas Voltage having positive effect on bead
width. As voltage increased reinforcement decreased, because voltage is directly to the
length of the current path between the welding wire and work-piece.so as the stick-out
increases voltage is also increases, due to that bead width is gradually increases and
reinforcement is decreases.
8. International Journal of Mechanical Engineering Research and Development (IJMERD), ISSN
2248 – 9347(Print) ISSN 2228 – 9355(Online), Volume 3, Number 2 April - May (2013)
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Fig.3Scatter diagram for reinforcement Vs voltage
Effect of current on reinforcement and width
Fig.4 Scatter diagram for width Vs current
Welding current is the most influential variable. It controls the rate at which welding
wire is burned off, the depth of fusion, and the amount of base metal fused. If the current is
too high, the depth of fusion will be too great and theWeld may melt through the backing. In
addition to this, the higher heat developed may excessively extend theHeat-affected zone of
the adjacent plate. Too high a current also means a waste of power and a waste of welding
wire in the form of excessive reinforcement. If the current is too low, there is insufficient
penetration and not enough reinforcement.As the current increases reinforcement and bead
width increases
Effect of speed on reinforcement and bead width
As the speed increases reinforcement decreases because as speed is increased heat
input per length of weld is decreased, Due to that weld deposition is smaller so as the Speed
increases reinforcement and width also decreases.fig. 5 show the direct effect of speed on
reinforcement.
9. International Journal of Mechanical Engineering Research and Development (IJMERD), ISSN
2248 – 9347(Print) ISSN 2228 – 9355(Online), Volume 3, Number 2 April - May (2013)
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Fig.5 Scatter diagram for reinforcement Vs speed
Effect of stick out on reinforcement and bead width
Stick-out in submerged arc welding means distance between plates to nozzle. As the
stick out increases reinforcement is increases and bead width decreases because as the
voltage increases weld width increases and reinforcement decreases. As voltage is directly to
the length of the current path between the welding wire and work-piece.so as the stick-out
increases voltage is also increases, due to that bead width is gradually increases Fig. 6 shows
the direct effect of nozzle to plate distance on weld width.
Fig.6 Scatter diagram for width Vs distance between plate and nozzle
Interaction Effect on reinforcement and bead width
Speed and Voltage on Reinforcement: Combined effect of speed and voltage is shown in
figure 7. For optimisation point of view Speed and voltage is most important parameters,
because the bead width and reinforcement is totally depends on speed and voltage. As the
speed increase reinforcement is increases and width is decreases.
10. International Journal of Mechanical Engineering Research and Development (IJMERD), ISSN
2248 – 9347(Print) ISSN 2228 – 9355(Online), Volume 3, Number 2 April - May (2013)
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Fig7 Interaction effect of speed and voltage on reinforcement
Fig.8 Interaction effect of speed and stick-out on reinforcement
from figure it is clear that, Reinforcement gradually decreases with increases in speed, as
speed is increased heat input per length of weld is decreased, Due to that weld deposition is
smaller so as the Speed increases reinforcement and width also decreases. As voltage
increased reinforcement decreased, because voltage is directly to the length of the current
path between the welding wire and work-piece.so as the stick-out increases voltage is also
increases,due to that bead width is gradually increases and reinforcement is decreases.
current and stick-out on reinforcement: Combined effect of current and stick-out on
reinforcement is shown in figure 6.7 From figure it is clear that,As the current increases
reinforcement Increases. Too high current also means waste of power & waste of welding
wire in the form of reinforcement .if the current is too low then there is insufficient
reinforcement occurredwhere as stick-out having positive effect on reinforcement
Speed and Stick-out on Reinforcement: Combined effect of speed and stick-out on
reinforcement is shown in figure 6.6. From figure it is clear that, Reinforcement Gradually
decreases with increases in speed. But as the stick-out increases reinforcement gradually
increases so from this it is clear that speed having negative result on reinforcement where as
stick-out having positive effect on reinforcement. As the speed is increased heat input per
length of weld is decreased, due to that weld deposition is smaller so as the Speed increases
reinforcement decreases.
11. International Journal of Mechanical Engineering Research and Development (IJMERD), ISSN
2248 – 9347(Print) ISSN 2228 – 9355(Online), Volume 3, Number 2 April - May (2013)
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Fig.9 Interaction effect of current and stick-out on reinforcement
Speed and Voltage on width: Combined effect of speed and voltage on width is shown in
figure 10. From figure it is clear that, Voltage is having Positiveeffect on bead width and
Speed having Negative effect on width. Width is gradually decreases with increases in speed,
as speed is increased heat input per length of weld is decreased, Due to that weld deposition is
smaller so as the Speed increases width and reinforcement also decreases. As voltage is
directly to the length of the current path between the welding wire and work-piece.so as the
stick-out increases voltage is also increases, due to that bead width is gradually increases.
Fig10 Interaction effect of speed and voltage on width.
CONCLUSION
The following conclusions were arrived at from the above investigations
• The two-level factorial techniques can be employed easily for developing
mathematical model for predicting weld –bead geometry within the workable region
of control parameters in saw welding.
• Response surface methodology can be used effectively in analysis the cause and the
effect of the process parameters on the response. The response surface methodology is
also used to draw contour graphs for various responses to show the interaction effect
of different process parameters.
• All of the response Viz reinforcement, Bead width decreases with increasing welding
speed.
12. International Journal of Mechanical Engineering Research and Development (IJMERD), ISSN
2248 – 9347(Print) ISSN 2228 – 9355(Online), Volume 3, Number 2 April - May (2013)
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• As the nozzle to plate distance increases weld width decreases but reinforcement
increases.
• In this research optimise value are cross checked by conformation test and it is found
satisfactory
• As per experiment optimse value for bead width is 18mm for that welding speed 20
inch per min, welding voltage 32 welding cueernt300amp, nozzle to plate distance
22mm are required and optimise value for reinforcement is 2.30 mm for that welding
speed 20 inch per min, welding voltage 32 welding cueernt340amp nozzle to plate
distance 22mm are required.
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