Parametric Optimization of Resistance Spot Welding Process

Abstract

In any manufacturing process the process parameters plays the vital role in manufacturing of the product which has the direct impact on the product and process also resulting in the burdensome loss to the industries implementing those processes. In resistance spot welding process the weld quality depends on a large degree of the weld penetration and weld geometry which is largely influenced by various process parameters in the process. Inadequacy of weld penetration and weld bead dimensions may lead to failure of the welded structure. Also the geometry of the flat surfaces may damage due to inadequate or incorrect input parameters. This paper is a study of optimization of process parameters using Taguchi methodology. Experimentation is carried out with the settings obtained by design of experiments were considered for the study. Response as weld time indicating weld quality is studied and mathematical model were developed correlating the important controllable spot welding process parameters like Voltage (V), wire diameter(D) and welding current (I), with weld bead time. Using these models the direct and interaction effects of the process parameters on weld bead time were studied and further the process parameters were optimized. The obtained results of mathematical model helped in selecting quickly the process parameters to achieve the desired quality.