Abstract
Euro-6 norms for reduction of CO2 emissions and ECE-R66-01 regulation for safer passenger transportation became legislative obligations for bus builders. These two adaptations increase the weight of a bus as nearly 600kg which also increases the fuel consumption nearly 1.5-3%. Dual phase (DP) steels can compensate these increases by decreasing the thickness of the components. Because, ferrite provides the steel with good formability and martensite increases the hardness and ultimate tensile strength in DP steels. This study focused on the multi response hybrid optimization of gas metal arc welding (GMAW) of DP1000 steel to determine the optimal parametric combination which gives the maximum ultimate tensile strength (UTS, MPa) and joint efficiency (JE) under minimum heat input (Q, kj/mm). Nine experimental trials which is based on the orthogonal array suggested by Taguchi method was carried out to investigate objective functions for optimization in the experimental range of GMAW parameters such as voltage (U, volt), welding speed (V, mm/min) and wire feed rate (f, m/min). The Taguchi method continued with Grey Relational Analysis (GRA) to overcome the multi-objective optimization model. Finally, Analysis of variance (ANOVA) method has been used to determine the significance of the welding parameters on the responses of UTS, JE and Q. This shows flexible applicability of Taguchi based GRA to find out the effect of each GMAW process parameters onto individual responses.
Highlights
The passenger safety, comfort and the fuel consumption are the most significant commercial factors for bus builders
Kumar et al [8] implemented the Taguchi method followed by grey relation analysis to optimize gas metal arc welding process parameters for multi performance characteristics of bead width and height, weld penetration and heat affected zone using AISI 1020 steel
Ambekar et al [14] presented a study by using Taguchi orthogonal array of L16for optimization of process parameters gas metal arc welding on AISI 410 steel
Summary
The passenger safety, comfort and the fuel consumption are the most significant commercial factors for bus builders. Chauhan et al [6] used Taguchi technique in GMAW process for optimization of gas metal arc welded AISI 1018 mild steel plates. Kumar et al [8] implemented the Taguchi method followed by grey relation analysis to optimize gas metal arc welding process parameters for multi performance characteristics of bead width and height, weld penetration and heat affected zone using AISI 1020 steel. Esme et al [11] optimized quality characteristics of the tungsten inert gas welding parameters such as weld bead, weld height, penetration, heat affected zone and ultimate tensile strength using Taguchi combined grey relational analysis method. Ambekar et al [14] presented a study by using Taguchi orthogonal array of L16for optimization of process parameters gas metal arc welding on AISI 410 steel. The analysis of variance (ANOVA) and confirmation test were applied in order to examine the contribution of each welding factors and to check the optimum results
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