Optimization of Resistance Spotwelding Parameters Using Taguchi Method

Shailesh Kumar Vishwakarma, Anurag Shrivastava, Sharmistha Singh


Resistance spot welding (RSW) is a major sheet metal joining process in many industries, such as the automobile, domestic appliances, and space craft fabrication. It is one of the oldest of the electric welding processes in use by industry today. Furthermore, other metal-to-metal connections, such as wire-to-wire joints in the electronics industry, are accomplished by resistance spot welding. Application-specific measures, such as the diameter of the welding spot, define the quality of the joint. The weld is made by a combination of heat, pressure, and time parameters. As the name implies, it uses the resistance of the materials to the flow of electric current that causes a localized heating in the parts to be joined. Understanding of physical mechanisms for easily manipulating and controlling weld qualities in advance is extremely important. This paper represents the optimization of various parameters of resistance spot welding. The experimental studies have been conducted under varying pressure, welding current, pressure, and welding time parameters. In this investigation the quality characteristic (tensile strength and nugget diameter) parameters have been considered using Taguchi Method. The experimental studies have been carried out by varying welding currents, welding pressure and weld times for joining two sheets. The results of the investigation indicate the welding current to be the most significant parameter controlling the weld tensile strength as well as the nugget diameter. The contribution of welding current, holding time and pressure to tensile strength are 61%, 29%, 4% respectively and the contribution of these parameters to nugget diameter are 81%, 1.7%, 17% respectively. Relationship graphs have been plotted between tensile strength and nugget diameter with parametric variations according to orthogonal array.

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DOI: https://doi.org/10.23956/ijermt.v6i7.211


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