International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 6, November - December (2013) IAEME

AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 6, November - December (2013), pp. 31-36 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

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ANALYSIS OF CO2 WELDING PARAMETERS ON THE DEPTH OF PENETRATION OF AISI 1022 STEEL PLATES USING RESPONSE SURFACE METHODOLOGY
Mr. Shukla B.A.(1),
(1)

Prof. Phafat N.G.(2)

Student, M.E. Manufacturing, Mechanical Engineering Department, J.N.E.C. Aurangabad, Maharashtra, India. (2) Associate Professor, Mechanical Engineering Department, J.N.E.C Aurangabad, Maharashtra, India.

ABSTRACT This paper concentrates on the analysis of CO2 arc welding parameters to maximize the depth of penetration using mathematical models based on Response Surface Methodology. Welding current, welding voltage, wire feed rate and gas pressure were taken as input parameters while the response was depth of penetration. Central Composite Design (CCD) was used for the experimental design. RSM based model has been developed to determine the depth of penetration attained by various welding parameters. The quadratic models developed using RSM shows high accuracy and can be used for prediction within the limits of the factors investigated. Keywords: CO2 arc welding, Depth of Penetration, AISI 1022, Response Surface Method. 1. INTRODUCTION Welding is an important manufacturing process which can join similar and dissimilar metals of different size and shapes. CO2 arc welding is the process which is widely used in automobile, aerospace/aircraft, heavy industrial manufacturing industries etc. For welded joints to retain longer life with high strength, depth of penetration plays an important role. The depth of penetration is the major response measured in all types of welding because if the penetration of the molten metal is not up to the mark, there will be occurrence of cavity which reduces the endurance of a component and the component eventually fails before the time of its duration. This causes a loss in terms of time, rejection of components and finally money loss.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 6, November - December (2013) IAEME

Due to all these problems the depth of penetration should be maintained at proper level during the welding operation. Most of the research work on the depth of penetration maximization focused on the optimization of parameters of welding operation for various metals and alloys. S.W. Campbell et al [1] performed ANN prediction of weld geometry using gas metal arc welding (GMAW) with alternate shielding gases. S.V. Sapakal and M.T. Telsang [2] has performed the parametric optimization of MIG welding using Taguchi design method. N.B. Mostafa and M.N. Khajavi [3] conducted an experiment on Flux cored arc welding (FCAW) with the help of sequential quadratic programming (SQP) to maximize the weld penetration. Vinod Kumar [4] had performed modeling of weld bead geometry and shape relationships using RSM technique. As depth of penetration is a very complicated phenomenon affected by many parameters such as current, voltage, gas pressure etc. Therefore, it is imperative to develop a reliable model that predicts the weld penetration to reduce the cost of welding. The important process parameters are determined based on the previous literature survey. An Response Surface Method (RSM) model is developed that predicts depth of penetration. RSM is selected because of its capability to learn and simplify from examples and adjust to changing conditions. 2. RESPONSE SURFACE METHODOLOGY Response Surface Methodology is one of the optimization techniques in describing the performance of the welding process and finding the optimum setting of parameters. RSM is a mathematical-statistical method that used for modeling and predicting the response of interest affected by some input variables to optimize the response [5]. RSM also specifies the relationships among one or more measured responses and the essential controllable input factors. When all independent variables are measurable, controllable and continuous in the process, with negligible error, the response surface model is as follows [5]: y= f(x1,x2,xn) (1)

where n is the number of independent variables. To optimize the response y, it is necessary to find an appropriate approximation for the true functional relationship between the independent variables and the response surface. Usually a second-order polynomial Equation (2) is used in RSM.
y = 0 + j x j + jj x 2 j + ij x i x j +
j =1 j =1 i j k k k 1 k

(2)

3. EXPERIMENTAL WORK AISI 1022 steel plates of 100 (length)*90 (width)*6 (thickness) was used as work piece material for square butt welding for the given study. AISI 1022 has lots of engineering applications specially in manufacturing sector. AISI 1022 is used by all industry sectors for applications involving welding plus lightly stressed carburised parts. Typical applications are General Engineering Parts and Components, Welded Structures etc. Also Carburised components like Camshafts, Light Duty Gears, Gudgon Pins, Ratchets, Spindles, Worm Gears etc. The chemical composition of AISI 1022 is shown in Table 1. Table 1. Chemical composition of AISI 1022 Steel Cr Ni Mo S P Si 0.02% 0.01% 0.01% 0.039% 0.050% 0.19%
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C Mn 0.206% 0.70%

Al 0.028%

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 6, November - December (2013) IAEME

In the present study four parameters namely welding current, welding voltage, wire feed rate and gas pressure were considered. For the measurement of depth of penetration optical microscope was used. A five level central composite design (CCD) was used to study linear, quadratic and two factor interaction effect between the four process variable and one response (Table 2). The upper limit of a factor was coded as +2 and the lower limit as -2, coded values for intermediate levels were calculated from the following relationship:

Xi =

2[2 X ( X max + X min )] X max X min

(3)

Where Xi is the required coded values of a variable X, X is any value of the variable from Xmin to Xmax. Xmin is the lower level of the variable and Xmax is the upper level of the variable. Table 2. Factors and their levels Current (A) Voltage(V) Wire feed rate(cm/min) 90 20 10.16 100 25 12.70 110 30 15.24 120 35 17.78 130 40 20.32

Sr. no 1. 2. 3. 4. 5.

Levels -2 -1 0 1 2

Gas pressure (psi) 20 30 40 50 60

4. RESULTS AND DISCUSSIONS For the depth of penetration regression Table 3. Shows the following. Table 3. Regression table for depth of penetration Coef SE Coef T 6.13857 0.08110 75.694 -0.04722 0.04380 -1.078 -0.71450 0.04380 -16.314 0.48800 0.04380 11.142 0.14633 0.04380 3.341 0.07167 0.04012 1.786 0.07299 0.04012 1.819 0.03174 0.04012 0.791 0.11799 0.04012 2.941 0.01300 0.05364 0.242 0.00800 0.05364 0.149 -0.03575 0.05364 -0.666 -0.03175 0.05364 -0.592 0.00200 0.05364 0.037 -0.02800 0.05364 -0.522 R-Sq(pred) = 80.62% R-Sq(adj) = 93.06%

Term Constant A V WF GP A*A V*V WF*WF GP*GP A*V A*WF A*GP V*WF V*GP WF*GP S = 0.214564

P 0.000 0.297 0.000 0.000 0.004 0.093 0.088 0.440 0.010 0.812 0.883 0.515 0.562 0.971 0.609

R-Sq = 96.30%

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 6, November - December (2013) IAEME

Linear effects: The p-value of current is 0.297 and is greater than 0.05 hence, it has no significant effect on depth of penetration. While the other parameters namely voltage, wire feed rate and gas pressure have p-values 0.000, 0.000 and 0.004 which are less than 0.05 hence, these parameters have significant effect on the model and depth of penetration. Squared effects: The p-value of the squared effect GP*GP = 0.01 is less than 0.05. Hence, this squared effect has significant effect. Interaction effect: All interaction effects are greater than 0.05. Therefore, there is no significant effects of these interaction values on the depth of penetration.

For each term in the model there is a coefficient. Using these coefficients we have construct equations, linear as well as quadratic representing the relationship between the response and the factors. DP = 6.37 - 0.0472 (A) - 0.714 V + 0.488 WF + 0.146 GP (4)

DP =6.13857-0.04722(A)-0.71450(V)+0.488(WF)+0.14633(GP)+0.07167(A)2+0.07299(V)2+ 0.03174(WF)2+0.11799(GP)2+0.013(A*V)+0.008(A*WF)-0.03575(A*GP)-0.03175(V*WF) +0.002(V*GP)-0.028(WF*GP) (5) The actual experimental values and model predicted values of depth of penetration is shown in Table 4. The values are in close proximity to each other and gives percentage error less than 7%. Table 4. Experimental design and RSM model adequacy check Wire feed Gas Predicted Current Voltage rate pressure value of (A) (V) (cms/min) (psi) Actual DP DP 110 30 20.32 40 7.01 7.342497 110 30 15.24 40 6.11 6.366497 120 35 17.78 50 6.11 6.239115 110 30 15.24 60 7.02 6.659164 110 30 15.24 40 6.11 6.366497 100 25 17.78 50 8.14 7.762546 110 40 15.24 40 5.12 4.937497 110 30 15.24 40 6 6.366497 110 30 15.24 40 6 6.366497 120 25 12.7 30 6.39 6.399449 120 25 17.78 50 7.7 7.668115 100 25 12.7 30 6.6 6.493879 110 30 15.24 40 6.3 6.366497 110 30 15.24 20 6.28 6.073831 110 30 15.24 40 6.28 6.366497 100 35 17.78 30 6.13 6.040879 120 35 17.78 30 6.25 5.946449 90 30 15.24 40 6.64 6.460928 120 35 12.7 30 4.8 4.970449 110 20 15.24 40 7.82 7.795497
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% Error

run order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

4.74 4.198 2.11 5.14 4.198 4.64 3.7 6.1 6.1 0.147 0.455 1.6 1.05 3.28 1.37 1.45 4.856 2.7 3.551 0.31

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 6, November - December (2013) IAEME

21 22 23 24 25 26 27 28 29 30 31

100 110 110 100 100 120 100 120 130 120 100

35 30 30 35 25 25 35 25 30 35 25

12.7 15.24 10.16 12.7 17.78 17.78 17.78 12.7 15.24 12.7 12.7

50 40 40 30 30 30 50 50 40 50 50

5.3 6.17 5.6 5.02 7.36 7.74 6.322 6.6 6.289415 5.5 6.65

5.357546 6.366497 5.390497 5.064879 7.469879 7.375449 6.333546 6.692115 6.272066 5.263115 6.786546

1.08 3.18 3.741 0.876 1.49 4.7 0.182 1.395 0.27 4.3 1.6

5. CONCLUSION This paper has investigated the process parameters of CO2 arc welding and their effects on depth of penetration with the use of Response Surface Methodology in square butt welding of AISI 1022 steel plates. The paper effectively describes the linear, square and interaction effects on the RSM based model. The conclusion of the present study were drawn as follows. RSM based models has been used to determine the depth of penetration attained by various drilling parameters. The models developed using RSM were reasonably accurate and can be used for prediction within the limits of factors investigated. From predicted values of RSM model and actual experimental values, the predicted and measured values are quite close, which indicates that the developed model can be effectively used to predict the depth of penetration. Also the highest percentage error noticed was 6.1%. The R2 value obtained in the regression table is 96.30% which itself is the evidence that the developed model is good enough for predicting the depth of penetration. Also, higher the value of R2 the better the model fits your data. Welding voltage and Wire feed rate was found to be the most significant factors for maximizing the depth of penetration followed by gas pressure. REFERENCES [1] S. W. Campbell, A. M. Galloway, And N. A. Mcpherson, Artificial Neural Network Prediction of Weld Geometry Performed using GMAW with Alternating Shielding Gases, WELDING JOURNAL, VOL. 91, (2012), June 174-181. S. V. Sapakal and M. T. Telsang, Parametric Optimization of MIG welding using Taguchi design method, International Journal of Advanced Engineering Research and Studies, Vol. 1, Issue 4, (2012), 28-30. N.B. Mostafa and M.N. Khajavi, Optimisation of welding parameters for weld penetration in FCAW, Journal of Achievements in Materials and Manufacturing Engineering, Vol. 16, Issue 1-2, (2006), 132-138. Vinod Kumar, Modelling of Weld Bead Geometry and Shape Relationships in Submerged Arc Welding using Developed Fluxes, Jordan Journal of Mechanical and Industrial Engineering, Vol. 5, (2011), 461-470. Ali Khorram, Majid Ghoreishi, Mohammad Reza Soleymani Yazdi, Mahmood Moradi, Optimization of Bead Geometry in CO2 Laser Welding of Ti 6Al 4V Using Response Surface Methodology, Scientific Research, 3, (2011), 708-712.
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[2]

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 6, November - December (2013) IAEME

[6]

K. Lalitnarayan, M.M.M. Sarcar, K. Mallikarjuna Rao and K. Kameshwaran, Prediction of Weld Bead Geometry for CO2 Welding process by Multiple Regression Analysis, International Journal Of Mathematics And Scientific Computing, Vol. 1, No. 1, (2011), 52-57. [7] M.R. Nakhaei, N. B. Mostafa Arab, Gh. Naderi and M. Hoseinpour Gollo, Experimental study on optimization of CO2 laser welding parameters for polypropylene-clay nanocomposite welds, Journal of Mechanical Science and Technology, 27 (3), (2013), 843-848. [8] MINITAB 16 (2010) Users manual, Version 16. [9] P.B.Wagh, R.R.Deshmukh and S.D.Deshmukh, Process Parameters Optimization for Surface Roughness in Edm for AISI D2 Steel by Response Surface Methodology, International Journal of Mechanical Engineering & Technology (IJMET), Volume 4, Issue 1, 2013, pp. 203 - 208, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [10] Aniruddha Ghosh and Somnath Chattopadhyaya,, Conical Gaussian Heat Distribution for Submerged Arc Welding Process, International Journal of Mechanical Engineering & Technology (IJMET), Volume 1, Issue 1, 2010, pp. 109 - 123, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [11] Ravi Butola, Shanti Lal Meena and Jitendra Kumar, Effect of Welding Parameter on Micro Hardness of Synergic MIG Welding of 304l Austenitic Stainless Steel, International Journal of Mechanical Engineering & Technology (IJMET), Volume 4, Issue 3, 2013, pp. 337 - 343, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [12] Aniruddha Ghosh and Somnath Chattopadhyaya,, Submerged Arc Welding Parameters Estimation Through Graphical Technique, International Journal of Mechanical Engineering & Technology (IJMET), Volume 1, Issue 1, 2010, pp. 95 - 108, ISSN Print: 0976 6340, ISSN Online: 0976 6359.

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