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.
Significancy Test For The Control Parameters Considered In Weld Bead Geometry...IJMER
Here in this work, an attempt has been made to find the interaction between control
parameters and weld bead geometry for fillet welding in mild steel specimen using Gas Metal Arc
Welding process. Accordingly control parameters have been adjusted to find the optimal bead geometry.
Initially the equations involving control parameters and bead geometry were developed by multiple
regression analysis method. The ANOVA technique is then employed to calculate the significant
difference between the means of the control parameters ,Also this justifies the range of the control
parameters considered for the experiment.
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.
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 Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Friction Stir Welding of Similar Metals by Taguchi Optimization Technique -A ...IJAEMSJORNAL
In order to meet the global competition and the survival of products in the market a new way of thinking is necessary to change and improve the existing technology and to develop products at economical price.This paper discusses use taguchi experiment design technique for maximizing tensile strength of friction stir welding AA6061 and AA6061. In friction stir welding, the joints are formed in the solid state by utilizing the heat generated by friction. The objectives of this study are obtaining friction weld element of aluminium 6061 to aluminium 6061 and optimising the friction stir welding parameters in order to establish the weld quality. Effect of tensile strength of friction stir welding process parameter (Rotational speed, travel speed, axial force and tilt angle) is evaluated and optimum welding condition for maximum tensile strength is determined.
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.
A review on Parametric Optimization of Submerged arc welding processIJSRD
Submerged arc welding is preferable more its inherent qualities such as Higher deposition rate, deeper penetration, control of variables, high quality, smooth finish. The bead geometry shows the quality of weld which is depends on input process parameters. The present work gives review of the effect of these Input parameters on weld bead geometry. Selection of process parameters has great influence on the quality of a welded connection. To automate a welding process, which is the present trend in any fabrication industry. It is also important that mathematical models have to be developed to relate the process variables to the weld bead parameters. All the welding processes are used with the aim of getting a welded joint with the desires weld bead geometry and excellent mechanical properties with a efficient quality welded joint at a relatively low cost with high productivity. Optimization designs concentrate on only one or two parameters, but in very more depth to gain a precise understanding of relationships between parameters.
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.
Significancy Test For The Control Parameters Considered In Weld Bead Geometry...IJMER
Here in this work, an attempt has been made to find the interaction between control
parameters and weld bead geometry for fillet welding in mild steel specimen using Gas Metal Arc
Welding process. Accordingly control parameters have been adjusted to find the optimal bead geometry.
Initially the equations involving control parameters and bead geometry were developed by multiple
regression analysis method. The ANOVA technique is then employed to calculate the significant
difference between the means of the control parameters ,Also this justifies the range of the control
parameters considered for the experiment.
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.
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 Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Friction Stir Welding of Similar Metals by Taguchi Optimization Technique -A ...IJAEMSJORNAL
In order to meet the global competition and the survival of products in the market a new way of thinking is necessary to change and improve the existing technology and to develop products at economical price.This paper discusses use taguchi experiment design technique for maximizing tensile strength of friction stir welding AA6061 and AA6061. In friction stir welding, the joints are formed in the solid state by utilizing the heat generated by friction. The objectives of this study are obtaining friction weld element of aluminium 6061 to aluminium 6061 and optimising the friction stir welding parameters in order to establish the weld quality. Effect of tensile strength of friction stir welding process parameter (Rotational speed, travel speed, axial force and tilt angle) is evaluated and optimum welding condition for maximum tensile strength is determined.
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.
A review on Parametric Optimization of Submerged arc welding processIJSRD
Submerged arc welding is preferable more its inherent qualities such as Higher deposition rate, deeper penetration, control of variables, high quality, smooth finish. The bead geometry shows the quality of weld which is depends on input process parameters. The present work gives review of the effect of these Input parameters on weld bead geometry. Selection of process parameters has great influence on the quality of a welded connection. To automate a welding process, which is the present trend in any fabrication industry. It is also important that mathematical models have to be developed to relate the process variables to the weld bead parameters. All the welding processes are used with the aim of getting a welded joint with the desires weld bead geometry and excellent mechanical properties with a efficient quality welded joint at a relatively low cost with high productivity. Optimization designs concentrate on only one or two parameters, but in very more depth to gain a precise understanding of relationships between parameters.
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.
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.
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.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950‟s and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
Optimization of tig welding using taguchi and regression analysisvivek bisht
In order to reduce the no of experiments required for finding the output .here we use these mathematically process in order to find output (in our case it is STRENGTH). without using further experiments
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
Optimization of tungsten inert gas welding on 6063 aluminum alloy on taguchi ...RSIS International
In this paper, the Taguchi method is used for the
Optimization of Tungsten Inert Gas Welding on 6063
Aluminum Alloy. The Taguchi method L27 is used to
optimize the pulsed TIG welding process parameters of 6063
aluminum alloy weldments for maximizing the mechanical
properties. Analysis of Variance is used to find the impact of
individual factors. Then the optimal parameters of the TIG
welding process is determined and the experimental results
illustrate the proposed approach.
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.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
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.
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
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
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Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
1. PARAMETRIC OPTIMISATION OF GAS METAL ARC WELDING PROCESS
WITH THE HELP OF TAGUCHI METHOD ON TENSILE STRENGTH – A REVIEW
Raj KumarYadav1
, Neeraj Jain2
, Kritika Thakur3
Faculty Department of Mechanical Engineering, AIST Sagar (M.P.)1
B.E. Scholar Department of Mechanical Engineering, AIST Sagar (M.P.)2,3
Abstract— Gas metal arc welding is a fusion welding process
having more importance in industry. This study aims to examine
the interaction between process parameters and tensile strength.
In this process proper selection of input welding parameters is
necessary in order to optimize fillet welded structure and
subsequently increase the productivity of the process. In order to
obtain a good quality weld, it is therefore, necessary to control
the input welding parameters For this, not only linear and the
curvilinear equations were developed to predict bead geometry,
but also interactions between process parameters and bead
geometry were analysed through sensitivity analysis. One of the
important welding output parameters in this process is tensile
strength affecting the quality and productivity of weldment. In
this research paper using Taguchi's method of design of
experiments a mathematical model was developed
using parameters such as, wire feed rate (W), welding voltage
(V), welding current. After collecting data, signal-to-noise ratios
(S/N) were calculated and used in order to obtain the optimum
levels for every input parameters.
Keywords - Gas Metal Arc Welding (GMAW), Tensile strength,
Taguchi Method, Signal-to- noise ratio.
1. INTRODUCTION
The GMAW has got wide applications in
industries due to the advantages such as high reliability, all
position capability, low cost, high productivity, and high
deposition rate, ease of use, absence of fluxes, cleanliness and
ease of mechanization. This process establishes an electric arc
between a continuous filler metal electrode and the weld pool,
with shielding from an externally supplied gas, which may be
an inert gas, an active gas or a mixture. The most important
gases which have been used in order to shield the weld pool
are Argon (Ar) Helium (He), CO2 and O2..The heat of the arc
melts the surface of the base metal and the end of the
electrode. The electrode molten metal is then transferred
through the arc the work piece where it combines with the
molten metal from the weld puddle and creates the weld bead.
In this welding process the quality of the weld joint can be
defined by many characteristics. One of these characteristics
is tensile strength which is the ratio of force per unit area. In
order to obtain a good quality weld and at the same time
consuming lesser amount of consumable such as material,
filler wire, gas, time and decreasing costs and subsequently
increasing productivity, it is therefore required to control the
input welding parameters of the gas metal arc welding
process. In this connection using the concept of loss function,
signal -to-noise ratios for tensile strength was utilized and
based on this the optimum levels for input welding parameters
were determined.
The method presented in this study is an experimental
design process called the Taguchi design method. Taguchi
design, developed by Dr. Genichi Taguchi, is a set of
methodologies by which the inherent variability of materials
and manufacturing processes has been taken into account at
the design stage. Although similar to design of experiment
(DOE), the Taguchi design only conducts the balanced
(orthogonal) experimental combinations, which makes the
Taguchi design even more effective than a fractional factorial
design. By using the Taguchi techniques, industries are able to
greatly reduce product development cycle time for both design
and production, therefore reducing costs and increasing profit.
The objective of the parameter design is to optimize the
settings of the process parameter values for improving
performance characteristics and to identify the product
parameter values under the optimal process parameter values.
The parameter design is the key step in the Taguchi method to
achieving high quality without increasing cost. The steps
included in the Taguchi parameter design are: selecting the
proper orthogonal array (OA) according to the numbers of
controllable factors (parameters); running experiments based
on the OA; analysing data; identifying the optimum condition;
and conducting confirmation runs with the optimal levels of
all the parameters.
Taguchi method the experimental procedure included
experimental design by Taguchi method, welding materials,
welding equipment and welding procedure. Taguchi method
can study data with minimum experimental runs. In this paper,
the design of experiment work can be decided by this method.
Steps of Taguchi method are as follows:
1. Identification of main function, side effects and
failure mode.
2. Identification of noise factor, testing condition and
quality characteristics.
3. Identification of the main function to be optimized.
4. Identification the control factor and their levels.
5. Selection of orthogonal array and matrix experiment.
6. Conducting the matrix experiment.
7. Analysing the data, prediction of the optimum level
and performance.
8. Performing the verification experiment and planning
the future action.
2. 2. DESIGN OF EXPERIMENTS
A. Experimental Procedure
The experiments were conducted using a semiautomatic
PARS MIG welding machine using direct current
electrode positive. Test pieces of size 20 mm diameter
were cut from ST-37 rod and their surfaces were ground to
remove oxide scale and dirt and moreover, consumable
electrode of 0.8 mm diameter was used for depositing the
weld beads on the base metal. Chemical composition of
base metal and filler wire is given in Table 1 andTable-2
respectively. Shielding of the gas puddle and molten metal
droplets from the electrode was carried out by a Gas mixture
of 80% argon and 20% CO2.
TABLE 1 THE CHAMICAL COMPOSITION OF FILLER WIRE
Element Cr P S Si Ti Mn C Fe
W% 0.031 0.007 0.01 0.024 0.002 0.417 0.113 Bal
TABLE 2 THE CHAMICAL COMPOSITION OF STEEL ST-37
Element Cr P S Si Ti Mn C Fe
W% 0.031 0.007 0.01 0.024 0.002 0.417 0.113 Bal
B. Development of Design Matrix
To select an appropriate orthogonal array for experiments,
the total degrees of freedom need to be computed. The
degrees of freedom are defined as the number of comparisons
between process parameters that need to be made to determine
which level is better and specifically how much better it is.
For example, a Three -level process parameter counts for three
degrees of freedom. The degrees of freedom associated with
interaction between two process parameters are given by the
product of the degrees of freedom for the two process
parameters. In the present study, the interaction between the
welding parameters is neglected. Once the degrees of freedom
required are known, the next step is to select an appropriate
orthogonal array to fit the specific task. Basically, the degrees
of freedom for the orthogonal array should be greater than or
at least equal to those for the process parameters. In this study,
an L09sss orthogonal array was used. The input welding
process parameters considered for this research work were
wire feed rate (W), welding voltage (V), welding current
(A).The output quality characteristic was dilution. All these
parameters were investigated on 3 levels. The welding input
variables and their limits are given Table 3. For avoiding
systematic errors further in carrying out the experiments, 09
experiments were randomized for placing bead-on-plate welds
on the ST-37 steel rod. The experimental layout for the
welding process parameters using L09 orthogonal array and
the experimental results for the weld bead dilution are shown
in Table 4
FIGURE NO. 1
FIGURE NO. 2
3. TABLE 3 WELDING VARIABLES AND THEIR LEVELS
Level
Variable Notation 1 2 3 Units
Wire
feed
rate
W 180 200 220 m/min
Arc
voltage
V 22.8 24 26 Volts
Welding
current
A 213.33 184.33 197.33 ampere
TABLE 4 EXPERIMENTAL RESULTS
Run
Number
V A W Tensile
Strength
S/N
Ratio
1. 1 1 1 638 140.150
2. 1 2 2 682 141.486
3. 1 3 3 667 141.041
4. 2 1 2 647 140.433
5. 2 2 3 688 141.661
6. 2 3 1 674 141.250
7. 3 1 3 684 141.545
8. 3 2 1 666 141.011
9. 3 3 2 669 141.101
3. ANALYSIS OF EXPERIMENTAL RESULTS BASED ON
TAGUCHI METHOD ANALYSIS OF S/N RATIO
According to Taguchi method, S/N ratio is the ratio of
“Signal” representing desirable value, i.e. mean of output
characteristics and the “noise” representing the undesirable
value i.e., squared deviation of the output characteristics. It is
denoted by η and the unit is dB. The S/N ratio is used to
measure quality characteristic and it is also used to measure
significant welding parameters.
According to quality engineering the characteristics are
classified as Higher the best (HB) and lower the best (LB).
HB includes T-S strength which desires higher values.
Similarly LB includes Heat Affected Zone (HAZ) for which
lower value is preferred.
The summary statistics Higher the best performance 09 the
best performance
4. ANALYSIS OF VARIANCE (ANOVA)
The main aim of ANOVA is to investigate the design
parameters and to indicate which parameters are significantly
affecting the output parameters. In the analysis, the sum of
squares and variance are calculated. F-test value at 95 %
confidence level is used to decide the significant factors
affecting the process and percentage contribution is
calculated. The ANOVA analysis for percentage calibration is
shown in Table-6
TABLE 5 RESULTS OF THE ANOVA
CF DOF SS MS %C
V 2 0.2142 0.1071 5.95
I 2 0.699 0.3495 19.42
W.F.R 2 1.247 0.6235 34.64
Error 2 1.44 0.72 39.99
Total 08 3.6002 1.8001 100
5. RESULTS AND DISCUSSIONS
According to ANOVA analysis as shown in Table-6, the most
effective parameters with respect to percentage calibration is
wire feed rate, welding current, contribution indicates the
relative power of a factor to reduce variation. For a factor with
a higher percent contribution, a small variation will have a
great influence on the performance. The percent contributions
of the welding parameters on the percentage calibration shown
in Table-6 According to this, wire feed rate was found to be
the major factor affecting the percentage calibration), whereas
welding current was found to be the second factor (19.42 %).
The percent contributions of voltage is lower (5.95%).
5.95
19.42
34.64
39.99
PIE CHART FOR %
CONTRIBUTION
VOLTAGE
CURRENT
WIRE FEED
RATE
FIGURE NO. 3
4. 6. CONCLUSIONS
This paper has presented an investigation on the
optimization and the effect of welding parameters on the
tensile shear strength of MIG welded galvanized steel rod.
The level of importance of the welding parameters on the
tensile shear strength is determined by using ANOVA. Based
on the ANOVA method, the highly effective parameters on
tensile shear strength were found as wire feed rate and
welding current, whereas voltage was less effective factors.
The results showed that voltage was about five times less
important than the first factor wire feed rate for controlling the
tensile strength. An optimum parameter combination for the
maximum tensile strength was obtained by using the analysis
of S/N ratio.
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