Modelling For Prediction And Optimization Of Mechanical Response Of Unequal Thickness Steel Sheet Resistance Spot Welds In Tensile-Shear Loading Condition

Hareshwara Ruban , Subramaniam (2013) Modelling For Prediction And Optimization Of Mechanical Response Of Unequal Thickness Steel Sheet Resistance Spot Welds In Tensile-Shear Loading Condition. Project Report. UTeM, Melaka. (Submitted)

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Abstract

Achieving good weld quality for resistance spot welding of unequal thickness steel sheet metal is increasingly becoming a major challenge especially in automobile industries. Generally the ‘trial and error’ method based on the knowledge and experience of the welder has been widely adopted by the industry for the selection the optimum weld control parameters in order to achieve good quality welds. An attempt was made hence to systematically find the optimum parameter selection by applying empirical data based statistical modelling methods. In this research, the strength on the tensile-shear testing of five different thicknesses; 0.5mm, 0.8mm, 1.0mm, 1.2mm and 1.5mm of galvanized steel sheet metal JIS G3302 SGCC was investigated by using resistance spot welding. Response Surface Methodology as a part of Design of Experiment was adopted with four parameters; weld current, electrode force, weld time and thickness at five levels to develop mathematical models. Two unequal thickness steel plates were welded together under the range of 13-23 kA weld current, 1.2 - 3.6 kN of holding force and 5 – 25 cycles of time used to conduct the experiment. The slope of the resistance spot welding is set to 00 degree and the total squeeze time for the welding fixed constant at 80msand the hold time at 50ms were kept constant. Analysis of variance (ANOVA) technique was used to check the adequacy of the model developed and F-test has been used for determining the most significant parameters affecting the spot weld parameters. The results showed, the weld current plays a major role in determining the maximum tensile strength.

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