Optimization of MIG Welding Parameters
Optimization of MIG Welding Parameters
Optimization of MIG Welding Parameters
As for materials, some are much easier to weld Arc welding use-s an electrical arc to melt the
work materials as well as filler material (sometimes welding voltage, current, wire speed and gas flow
called the welding rod) for welding joints. Arc rate were studied. The experiments were conducted
welding involves attaching a grounding wire to the based on a four-factor, three-level, face centred
welding material or other metal surface. Another composite design matrix. The empirical
wire known as an electrode lead is placed on the relationship can be used to predict the yield
material to be welded. Once that lead is pulled strength of inert gas metal arc welded AISI 1040
away from the material, an electric arc is generated. medium carbon steel. Response Surface
It's a little like the sparks you see when pulling Methodology (RSM) was applied to optimizing the
jumper cables off a car battery. The arc then melts MIG welding process parameters to attain the
the work pieces along with the filler material that maximum yield strength of the joint.
helps to join the pieces.
III. PROBLEM DESCRIPTION
Feeding the filler into the welding joint takes
Objective of the work
steady hands and an eye for detail. As the rod
melts, the welder must continuously feed the filler In this thesis, materials AISI 1050 Mild Steel are
into the joint using small, steady, back-and-forth welded by varying process parameters welding
motions. These motions are what gives welds their speed, welding current and welding voltage. Effect
distinctive appearance. Going too fast or slow, or of process current on the tensile strength of weld
holding the arc too close or far away from the joint will be analysed.
material can create poor welds.
EXPERIMENTAL PROCEDURE
Shielded metal arc welding (SMAW or stick
In this thesis, experiments are made to understand
welding), gas metal arc welding (more
the effect of MIG welding parameters welding
commonly known as metal inert gas, or MIG,
speed, welding current and welding voltage on
welding) and gas tungsten arc welding
output parameters such as hardness of welding,
(frequently called tungsten inert gas, or TIG,
tensile strength of welding.
welding) all exemplify arc welding.
MIG welding experimental images
These three common methods each offer unique
advantages and drawbacks. Stick welding, for
instance, is inexpensive and easy to learn. It's also
slower and less versatile than some other methods.
Oppositely, TIG welding is difficult to learn and
requires an elaborate welding rig. TIG welding
produces high-quality welds, however, and can
weld materials that other methods can't.
Torch welding represents another popular welding
method. This process typically uses an MIG welding machine
oxyacetylene torch to melt the working material
and welding rod. The welder controls the torch and
rod simultaneously, giving him or her a lot of
control over the weld. While torch welding has
become less common industrially, it's still
frequently used for maintenance and repair work,
as well as in sculptures (more on that later).
II. LITERATURE REVIEW
Work pieces (AISI 1050 STEEL)
Gas Metal Arc Welding (GMAW), sometimes
referred to by its subtypes Metal Inert Gas (MIG)
welding or Metal Active Gas (MAG) welding, is a
semi-automatic or automatic 0020 Arc welding
process in which a continuous and consumable
wire electrode and a shielding gas are fed through a
welding gun. A constant voltage, direct current
power source is most commonly used with
GMAW, but constant current systems, as well as
alternating current, can be used. In this research
work an attempt was made to develop a response
surface model to predict tensile strength of inert
gas metal arc welded AISI 1040 medium carbon
steel joints. The process parameters such as Dumbbell shape work pieces for tensile test
Welding process
For the experiment, welding parameters selected
are shown in table.
The welding current and electrodes considered are
PROCESS LE LEVEL LEVEL
PARAMETERS VEL1 2 3
WELDING 180 230 280
CURRENT
(AMP)
WELDING 200 300 400
SPEED (m. m/s)
WELDING 22 24 26
VOLTAGE (V) INTRODUCTION TO TAGUCHI
TECHNIQUE
WELDING WELDING WELDING
CURRENT SPEED (m. VOLTAGE • Taguchi defines Quality Level of a
(AMP) m/s) (V) product as the Total Loss incurred by
society due to failure of a product to
180 200 22
perform as desired when it deviates from
180 300 24
the delivered target performance levels.
180 400 26
230 200 22 • This includes costs associated with poor
230 300 24 performance, operating costs (which
230 400 26 changes as a product ages) and any added
280 200 22 expenses due to harmful side effects of the
280 300 24 product in use.
280 400 26 Taguchi Methods
● Help companies to perform the Quality
WELDIN ULTIMAT Fix!
WELDIN
WELDIN G E
G
G SPEED VOLTAG TENSILE ● Quality problems are due to Noises in the
CURREN product or process system
(m. m/s) E (V) STRENGT
T (AMP)
H (MPa) ● Noise is any undesirable effect that
180 200 22 375 increases variability
V. RESULTS
Taguchi method stresses the importance of
studying the response variation using the signal–
to–noise (S/N) ratio, resulting in minimization of
quality characteristic variation due to
Analyse Taguchi Design – Select Responses uncontrollable parameter. The cutting force is
considered as the quality characteristic with the
concept of "the larger-the-better". The S/N ratio for
the larger-the-better is:
S/N = -10 *log(Σ(Y2)/n))
Where n is the number of measurements in a
trial/row, in this case, n=1 and y is the measured
value in a run/row. The S/N ratio values are
Terms calculated by taking into consideration above Eqn.
with the help of software Minitab 17.
The force values measured from the experiments
and their corresponding S/N ratio values are listed
in Table
VI. CONCLUSION
The experiment designed by Taguchi method
fulfils the desired objective. Fuzzy interference
system has been used to find out the ultimate
tensile strength. The all possible values of have
been calculated by using MINITAB 17.0 software.
Analysis of variance (ANOVA) helps to find out
the significance level of each parameter. The
optimum value was predicted using MINITAB-17
software.
The welding parameters are Welding current,
welding voltage and welding speed for MIG
welding of work piece AISI1050 steel. In this
work, the optimal parameters of welding speed are
200m.m/s, 300 m.m/s & 400 m.m/s, welding
S/N ratio plot current are 180, 230 &280 amps, and welding
voltage are 22, 24 &26 volts. Experimental work is
conducted by considering the above parameters.
Ultimate tensile strength validated experimentally.
The experimental results confirmed the validity of
the used Taguchi method for enhancing the
welding performance and optimizing the welding
parameters in MIG welding at welding speed 400
m.m/s, welding voltage 26 volts and welding
current 180 amps
VII. REFERENCES
[1]. Optimization of mig welding process
parameters to predict maximum yield
strength in aisi 1040 ajit hooda1*, ashwani
Means plot dhingra2 and satpal sharma2
[2]. A Review on Optimization of MIG Welding