International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017
p-ISSN: 2395-0072
www.irjet.net
OPTIMIZATION OF RESISTANCE SPOT WELDING PROCESS PARAMETERS OF AISI 304L AND AISI 1020 WELDED JOINTS H.A. Shende1 and N.A. Kadam2 1M.E.Student, 2Assistant
Department of Mechanical Engineering, M.G.M’s C.O.E., Nanded, MH., India
Professor, Department of Mechanical Engineering, M.G.M’s C.O.E., Nanded, MH., India
---------------------------------------------------------------------***--------------------------------------------------------------------2. LITERATURE REVIEW Abstract - This dissertation report aimed on an optimization of resistance spot welding process by the effects of process parameters applying Taguchi methods to improve the quality of manufacturing goods and engineering development of designs for studying variation. A sound weld from spot welding is what most of the manufacturers desired and preferred for mechanical assemblies in their systems. The robustness is mainly relied on joining mechanism of mechanical parts. In this research, the effect of spot welding parameters on tensile strength (T.S.) and nugget diameter (N.D.) was investigated using Taguchi method. The main affecting welding parameters such as weld current, weld time, pressure and holding time were determined as the basis for quality evaluation. The welded samples are later undergone the tensile test and metallurgical test to characterize the spot weld growth. Taguchi quality design concepts of L9 orthogonal array has been used to determine Strength to Noise (S/N ratio), Analysis of Variance (ANOVA) and F test value for determining most significant parameters affecting the spot weld performance.
Key Words: Resistance spot welding, tensile strength, nugget diameter, ANOVA, grey relational analysis.
1. INTRODUCTION The quality and mechanical behavior of resistance spot welds (RSW) significantly affects durability and crashworthiness of vehicle. Dissimilar resistance spot welding can be more complex than similar welding due to different thermal cycle experienced with each metal. Despite of various application of dissimilar RSW, reports in the literature dealing with mechanical behaviors of them are limited.
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Mehdi Mansouri et.al.[1] observed that compared to similar welds, weld nugget of dissimilar SS/CS RSWs has two distinct features: asymmetrical shape (FZ size of SS side is greater than that of for CS side due to its higher resistivity)and shifting of final solidification line from sheet/sheet interface into the SS side. Mahadzir Ishak et.al. [2] carried out resistance spot welding of AISI 301 stainless steel and AISI 1020 carbon steel. They reported that the optimum weld condition, (I=5 KA, WT 3 cycle and electrode force 40 psi) achieved highest tensile strength (200.71 MPa) and Charpy impact energy (46 J). Nachimani Charde [3] carried out spot welding of dissimilar materials with different thicknesses. He analyzed that hardness increments of welded side do exist because of heat treatment that happened during welding process. A.G. Thakur et.al. [4] investigated the effect of welding parameters on the tensile shear strength of spot welded galvanized steel sheets. Pirooz Marashi et.al. [5] concluded that in dissimilar RSW between low carbon galvanized steel and austenitic stainless steel, asymmetric fusion zone was obtained due to their different electrical resistivity and thermal conductivity. A.S. Panchakshari et.al.[6] carried out an optimization of process parameters in resistance spot welding using genetic algorithm. Oscar martin et.al. [7] observed that in resistance spot welding of 304 austenitic stainless steel of 0.8 mm thickness, the weld nugget grows at the expense of heat input that increases with increasing welding current and weld time. Nachimani Charade [8] invested spot weld growth on dissimilar joints of 304l austenitic stainless steel and medium carbon steel. He concluded that Force increment has caused diameters decrement which decreases bonding strength of weld pairs. Majid Pournavari et.al. [9] conducted experimentation on effect of weld nugget size on overload failure mode of resistance spot welds. Rajprasad Rajkumar et.al. [10] observed that hardness of welded zones of 304 austenitic ISO 9001:2008 Certified Journal
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