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Abstract
In this study, experiments were designed on the basis of response surface method to determine the effects of current, time and electrode pressure on weld nugget diameter using the Design Expert software. The experimental results were employed to develop a mathematical model which is able to predict linear, quadratic and two-factor interactive effects of these parameters on weld nugget diameter of St12 steel with 0.8mm thickness. Adequacy of the model was checked with the help of scatter diagrams and analysis of variance (ANOVA). The predicted results indicated that increase in current and time at low and medium values increased the weld nugget diameter but at higher values due to interactive effects of parameters their increase caused a decrease in weld nugget diameter. Current increase at constant pressures had a similar effect on weld nugget diameter. The developed model was also used to maximize the weld nugget diameter using the above mentioned software. The optimization results showed that weld nugget diameter obtained a maximum value of about 5.80 mm at 10.64 KA current, 9 cycles and 2 bar electrode pressure.
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References
- Chao, J., Morkey N. 2003. Ultimate Strength and Failure Mechanism of Resistance Spot Weld Subjected to Tensile, or combined Tensile/Shear Loads, Journal of Engineering Materials and Technology 25:125-133
- Pouranvari, M., Asgari, H.A., Marashi, M.H., Goodarzi, M. 2003. Effect of weld nugget size on overload failure mode of resistance spot welds in : Journal of Science and Technology of Welding and Joining 2: 223-231.
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- Khuri, A., Cornell, J. A. 1996. Response Surfaces Design and Analysis, Marcel Dekker, 2nd edition, New York.
- Cho, J. A., Li, W., Hu, S. J. 2007. Design of Experiment Analysis and Weld Lobe Estimation for Aluminum Resistance Spot Welding, Welding Journal 9: 45-51.
- Han, Y., Byeong, M., Li, K., H., Park, Y. K. 2009. Strength Characteristics on Resistance Spot Welding of Al Alloy Sheets by Taguchi Method, International Journal of Modern 20:4297-4320.
- Lin, L., T., Chou, Chou, C. P. 2008. Modelling and optimization of the Resistance Spot Welding Process via a Taguchi–Neural Approach in The Automobile Industry.
- Yi, Luo., Hong, Ye., Xiong, Cheng Zhi., Lin, Xu. 2009.Resistance Spot Welding Process of Galvanized Steel Sheet Based on Regression Modeling, Journal of Material Science Forum 610:681-689.
References
Chao, J., Morkey N. 2003. Ultimate Strength and Failure Mechanism of Resistance Spot Weld Subjected to Tensile, or combined Tensile/Shear Loads, Journal of Engineering Materials and Technology 25:125-133
Pouranvari, M., Asgari, H.A., Marashi, M.H., Goodarzi, M. 2003. Effect of weld nugget size on overload failure mode of resistance spot welds in : Journal of Science and Technology of Welding and Joining 2: 223-231.
American Welding Society 1997. Recommended practices for test methods for evaluating the resistance spot Welding Behavior of Automotive Sheet Steel Materials, ANSI/AWS/SAE/D8.9-97.
Khuri, A., Cornell, J. A. 1996. Response Surfaces Design and Analysis, Marcel Dekker, 2nd edition, New York.
Cho, J. A., Li, W., Hu, S. J. 2007. Design of Experiment Analysis and Weld Lobe Estimation for Aluminum Resistance Spot Welding, Welding Journal 9: 45-51.
Han, Y., Byeong, M., Li, K., H., Park, Y. K. 2009. Strength Characteristics on Resistance Spot Welding of Al Alloy Sheets by Taguchi Method, International Journal of Modern 20:4297-4320.
Lin, L., T., Chou, Chou, C. P. 2008. Modelling and optimization of the Resistance Spot Welding Process via a Taguchi–Neural Approach in The Automobile Industry.
Yi, Luo., Hong, Ye., Xiong, Cheng Zhi., Lin, Xu. 2009.Resistance Spot Welding Process of Galvanized Steel Sheet Based on Regression Modeling, Journal of Material Science Forum 610:681-689.