Prediction of weld strength by parametric optimization of resistance spot welding using Taguchi method

Abstract

This paper reports on parametric analysis of multi spot welded lap shear and cross tension specimen to analysis the effect of process and design parameters of welding on the tensile shear strength and tensile strength respectively. Further, study is carried out by using regression modeling to develop mathematical equations which shows relationship between selected welding parameters and weld strength. The experimental studies were conducted by considering welding force and welding current as process parameters whereas specimen thickness, number of spots and distance between the spots as design parameters. As per Taguchi experimental design approach, five welding parameters were considered for an investigation. Experimentation is carried out as per L27 orthogonal array to investigate the impact of process and design parameters on weld quality. Analysis of variance (ANOVA) used to determine the level of importance selected process and design parameters on weld strength. By using the analysis of signal to noise (S/N) ratio the optimum welding parameter combination was obtained. Confirmation tests exhibit that there is maximum 0.571741 % deviation between the results of tensile shear strength obtained by experimentation and regression equation for lap shear specimen. Similarly, deviation between results of tensile strength obtained by experimentation and obtained regression equation for cross tension specimen is 0.85744 %. Taguchi method was used to enhance the performance of the resistance spot welding process, which was confirmed by obtained experimental results.This paper reports on parametric analysis of multi spot welded lap shear and cross tension specimen to analysis the effect of process and design parameters of welding on the tensile shear strength and tensile strength respectively. Further, study is carried out by using regression modeling to develop mathematical equations which shows relationship between selected welding parameters and weld strength. The experimental studies were conducted by considering welding force and welding current as process parameters whereas specimen thickness, number of spots and distance between the spots as design parameters. As per Taguchi experimental design approach, five welding parameters were considered for an investigation. Experimentation is carried out as per L27 orthogonal array to investigate the impact of process and design parameters on weld quality. Analysis of variance (ANOVA) used to determine the level of importance selected process and design parameters on weld strength. By using the analysis of signal to no...