Beruflich Dokumente
Kultur Dokumente
Assistant Professor, Mechanical Engineering Department, Shri Vishnu Engineering College For Women, Andhra
Pradesh, India,
ashokkumark@svecw.edu.in, satishg@svecw.edu.in, lakshminarayanav@svecw.edu.in, srinivasraon@svecw.edu.in
Abstract
GAS TUNGSTEN ARC WELDING (GTAW) is the quality weld process. It is preferred welding process for stainless steel, low alloy
steel, nickel, cobalt, titanium, aluminum, copper, and magnesium. The present work aims to evaluate the effect of Gas Tungsten Arc
Welding process parameters on the quality of the weld bead. The process parameters Welding Current, Wire Diameter, Wire Feed
Speed, Ratio of wire feed rate to travel speed and Plate thickness are taken as a input variables for this present work. The quality of
the weld bead can be assessed by the bead characteristics such as Penetration, Reinforcement & Width. Experiments were conducted
to study the effects of the welding process parameters. Statistically designed experiments with 5 process parameters (each at 3 levels)
are conducted to study the effect of these parameters on bead geometry. It is found from the analysis of variance (ANOVA) that the
wire feed rate, travel speed and wire diameter are the main parameters that influence bead geometry in GTAW. Mathematical models
are developed for depth of penetration, reinforcement height and bead width for GTAW using the multiple regression analysis.
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Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
185
Factors
Level
2
3
4
7
15
4
5
2
2
2
2
2
3
3
Factorial design
Total no. of
experiments
4(22)
8(23)
16(24)
128(27)
32768(215)
81(34)
243(35)
Taguchi
Design
4
4
8
8
16
9
18
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186
Number
of
Rows
4
8
9
12
16
16
18
25
27
32
32
36
36
50
54
64
64
81
Maximum
No
of
factors
3
7
4
11
15
5
8
6
13
31
10
23
16
12
26
63
21
40
Maximum
no
of
columns At these levels
2
3
4
5
3
7
4
11
15
5
1
7
6
13 31
1
9
11
12 3
13 1
11
1
25 63
21 40 -
Ve
e/fe
1.4.1 Variance
The variance of each factor is determined by the sum of the square
of each trial sum result involving the factor, divided by the degrees
of freedom of the factor. Thus
VA
=
SA/fA (for factor A)
VB
=
SB/fB (for factor B)
VC
=
SC/fC (for factor C)
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187
Table -3: L18 (21 37) Orthogonal Array & its Linear Graph.
Volume V1
Expt.
No
1
2
3
4
5
6
Column
1 2
1 1
1 1
1 1
1 2
1 2
1 2
3
1
2
3
1
2
3
4
1
2
3
1
2
3
5
1
2
3
2
3
1
6
1
2
3
2
3
1
7
1
2
3
3
1
2
7
8
9
10
11
12
1
1
1
2
2
2
1
2
3
1
2
3
2
3
1
3
1
2
1
2
3
3
1
2
3
1
2
2
3
1
2
3
1
2
3
1
13
14
15
16
17
18
2
2
2
2
2
2
3
3
3
1
1
1
2
2
2
3
3
3
1
2
3
1
2
3
2
3
1
3
1
2
3
1
2
2
3
1
1
2
3
3
1
2
3
1
2
1
2
3
(2)
8
1
2
3
3
1
2
(3)
Efficiency
(4)
% of dilution
(5)
3
1
2
1
2
3
2
3
1
2
3
1
2. DESIGN OF EXPERIMENTS.
The process parameters selected for the present study are Welding
current, wire diameter, wire feed rate, ratio of wire feed rate to
travel speed, and plate thickness. The ratio of wire feed rate to
travel speed (WFR/TS) is chosen as a factor instead of travel speed
to avoid the erratic combinations such as high travel speed for low
feed rate etc. Three levels are chosen for all the process parameters
(also called factors). These selected factors and their levels are
given in Table 4.
Table -4: Factors and their levels used in GTAW experiments
Parameters
Notation
Factor Levels
1
2
Current(A)
140
160
180
Wire
diameter(mm)
1.2
1.4
1.6
WFR
1500
2000
2500
WFR/TS
10
PT
12
16
Wire
feed
rate(mm/min)
Ratio of wire
feed rate to
travel speed
(mm)
Pipe thickness
Heat input J
Experi
mental
Numb
er
E01
E02
E03
E04
E05
E06
E07
E08
E09
E10
E11
E12
E13
E14
E15
E16
E17
E18
Curre
nt (A)
Wire
Diamet
er
(mm)
Wire
Feed
Rate
(mm/
min)
140
140
140
160
160
160
180
180
180
140
140
140
160
160
160
180
180
180
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1000
2000
3000
1000
2000
3000
2000
3000
1000
3000
1000
2000
2000
3000
1000
3000
1000
2000
Ratio
of wire
feed
rate to
travel
speed
6
8
10
8
10
6
6
8
10
10
6
8
10
6
8
8
10
6
Plate
Thickne
ss (mm)
8
12
16
12
16
8
16
8
12
12
16
8
8
12
16
16
8
12
10
WFR/TS
1000
166.67
125
100
2000
333.33
250
200
3000
500
375
300
(1)
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188
3. RESULTS
From the microscopic examination we find penetration,
reinforcement & width and further calculations like percentage of
dilution, heat input (J), weld bead volume (V1), wire deposition
volume (V2) and wire deposition efficiency were done by using
the formulas.
E14
E15
E16
E17
E18
0.96
0.58
0.65
0.46
1.08
4512
1976
3375
1523
3975
4620
2011
3394
1540
4023
97.66%
98.25%
99.43%
98.86%
98.81%
Penetration
(P) mm
Reinforcement
(R) mm
E01
E02
E03
E04
E05
E06
E07
E08
E09
E10
E11
E12
E13
E14
E15
E16
E17
E18
0.75
0.91
1.96
0.82
1.31
2.25
1.76
1.91
1.18
0.75
0.91
0.98
0.76
2.41
2.18
1.78
1.14
2.1
1.95
2.26
4.95
1.96
3.21
5.14
2.75
3.12
2.1
1.95
2.28
2.58
2.34
4.05
2.98
2.53
1.65
2.93
Width
(W)
mm
5.25
7.45
4.83
3.22
3.78
10.45
6.34
7.22
3.28
7.13
6.34
8.28
4.12
9.24
3.04
5.98
3.02
9.6
%
of
Dilution
27.78
28.13
28.57
28.57
28.89
30.67
39.13
38.78
37.50
27.78
28.13
27.93
25.81
37.50
39.22
40.00
34.48
39.62
Experimental
Number
Heat
input
(J)
kJ/mm
E01
E02
E03
E04
E05
E06
E07
E08
E09
E10
E11
E12
E13
0.84
0.50
0.36
0.58
0.41
0.96
1.08
0.65
0.46
0.36
0.84
0.50
0.41
Weld
Bead
Volume
(V1)
mm3
1114
3000
5880
1120
2993
5906
2208
4533
2005
3308
1512
3938
2224
Wire
deposition
(V2)
mm3
Wire
deposition
efficiency
1131
3080
6034
1131
3080
6034
2263
4620
2011
3394
1540
4023
2263
98.44%
97.40%
97.44%
98.99%
97.16%
97.88%
97.58%
98.11%
99.67%
97.44%
98.18%
97.89%
98.29%
A
1.043
1.622
1.645
0.602
3
B
1.103
1.432
1.775
0.672
2
C
1.163
1.303
1.843
0.680
1
D
1.697
1.430
1.183
0.513
4
E
1.298
1.362
1.650
0.352
5
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189
Level
1
2
3
Delta
Rank
1.8
1.6
Mean of Means
1.4
1.2
1.0
140
160
180
1.2
1.4
1.6
1000
2000
3000
1.8
A
2.662
3.280
2.513
0.767
3
B
2.247
2.762
3.447
1.200
2
C
2.153
2.678
3.623
1.470
1
D
3.183
2.572
2.700
0.612
4
E
2.797
2.542
3.117
0.575
5
1.6
1.4
1.2
A
3.6
1.0
6
10
12
16
3.2
Mean of Means
2.8
2.4
2.0
140
160
180
1.2
1.4
1.6
1000
2000
3000
3.6
3.2
2.8
2.4
2.0
6
10
12
16
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190
A
6.547
5.642
0.905
5
B
5.340
6.175
1.240
4
C
4.025
6.595
3.450
2
D
7.870
5.865
3.510
1
E
6.390
6.653
1.602
3
v.
Mean of Means
6
5
4
140
160
180
1.2
1.4
1.6
1000
2000
7
6
5
4
6
Y = 10aX1bX2cX3dX4eX5f
3000
10
12
16
P=
-- (5.1)
Reinforcement
R=
-- (5.2)
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191
--- (5.1)
DF
Regressio
n
Error
Total
5
12
17
Sum of
Square
s
4.8066
1.2295
6.0362
Mean
Square
0.96133
0.10246
F
Rati
o
9.38
23
Prob(F)
0.00079
Penetratio
n (P) mm
0.75
0.91
1.96
0.82
1.31
2.25
1.76
1.91
1.18
0.75
0.91
0.98
0.76
2.41
2.18
1.78
1.14
2.1
Calculate
d (P)
0.63
1.19
1.84
0.80
1.47
2.13
1.75
1.72
1.40
0.97
1.14
1.24
0.81
2.04
1.51
1.82
0.91
2.54
Residual
-0.12
0.28
-0.12
-0.02
0.16
-0.12
-0.01
-0.19
0.22
0.22
0.23
0.26
0.05
-0.37
-0.67
0.04
-0.23
0.44
%
Error
-15.85
30.23
-6.22
-2.77
11.98
-5.22
-0.45
-9.73
18.34
29.44
25.48
26.54
6.68
-15.44
-30.76
2.07
-19.75
20.84
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192
CONCLUSIONS
1.
2.
REFERENCES
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[2]
[3]
[4]
[5]
[6]
[7]
[8]
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[10]
[11]
[12]
[13]
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BIOGRAPHIES
Mr. K. Ashok Kumar working as an Assistant
Professor in the Department of Mechanical
Engineering at Shri Vishnu Engineering College
for Women, Bhimavaram. Mr. K.Ashok Kumar
obtained his B.E first class at TJIT, Channai,
M.Tech first class with distinction from GIET, Rajahmundry
and have 1year industrial and 2years teaching experience.
Mr. G. Satish working as an Assistant Professor
in the Department of Mechanical Engineering at
Shri Vishnu Engineering College for Women,
Bhimavaram and obtained his B.Tech and
M.Tech(Machine Design) degrees both with
first class at JNTUK. He has experience of 2years as CAD
engineer and 2years teaching and published 1 international
journal.
Mr. V. Lakshmi Narayana working as an
Assistant Professor in the Department of
Mechanical Engineering at Shri Vishnu
Engineering College for Women, Bhimavaram.
He has completed his B.Tech in the discipline of
Mechanical and M.Tech in CAD/CAM. He did both degrees
in first class with distinction. He has work experience of 1
year as CAD Engineer and 4 years as an Assistant Professor.
Mr. N. Srinivasa Rao working as an Assistant
Professor in the Department of Mechanical
Engineering at Shri Vishnu Engineering College
for Women, Bhimavaram. He has completed his
B.Tech in the discipline of Mechanical and
M.Tech in Automobile Engineering in NIT Warangal. He did
both degrees in first class. He has 3 years as an Assistant
Professor in teaching.
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193