Integrated Product Design And Optimization Of Multiplex Electrode Holder For ARC Welding Process

Chew, Lai Huat (2011) Integrated Product Design And Optimization Of Multiplex Electrode Holder For ARC Welding Process. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

The main challenge for this project was to design and fabricate a Multiplex Electrode Holder (MEH) that can perform two fundamentally different welding process such as a manual Shielded Metal Arc welding (SMAW) and Gas Metal Arc Welding (GMAW) by integrating the features of both welding processes together in a single setup. The efficiency welding performance for MEH, also was investigated by develop a solution to control the feed-rate of the electrode, so and to preserve the stability of the arc during the welding process of SMAW in MEH. In order to do that, this project also included four parameter conditions toexperiment MEH, to assess the efficacy on performed both SMAW and GMAW. The optimization of the design of the MEH by analyzing its performance from the experimental results by preserving and improving of the stability of the arc during GMAW processes. Enhancement of the welding performance of SMAW by appropriate design modification in electrode holder was also done by making eight conceptual design of Multiplex Electrode holder using 3D CAD software to develop a Morphology Chart. This project involves a detailed conceptual and working model design of Multiplex Electrode Holder and experimental investigation to improve welding performance of both SMAW and GMAW processes. 3D CAD software’s is extensively used to make the conceptual as well as detailed working models of MEH and later for design optimization. For data analysis, Regression method was used to analyze the data. Four welding condition such as the welding current, arc voltage, welding speed and electrode feed-rate were chosen as the experiment parameters. After experiment completed, ANOVA is used investigate which welding process parameters significantly affect the performance characteristic. This is an accomplishment by separating the total variability of the relation grades, which is measured by the sum of the squared deviations from the total mean of the relation grade, into contribution by each welding process parameter and the error.

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