Analysis and modeling of the effects of process parameters on specific cutting energy in robotic welding machine MIG

Hazam Nor, Isma Dienny Hakim (2024) Analysis and modeling of the effects of process parameters on specific cutting energy in robotic welding machine MIG. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The manufacturing industry has enormous impact on the economic well-being of many industrialised nations, both existing and developing. Malaysia’s annual energy consumption increased by 6.64%, with manufacturing sector contributing to 79% of total energy consumption, emphasizing the importance of developing sustainable practices. The study focused on the robotic welding machine MIG, contribute to energy consumption in manufacturing. The research examines the neccesity to investigate the effects of the process parameters specific cutting energy. The study adopts a Design of Experiment technique, employing an Orthogonal Array (L27) to collect data on robotic welding machine MIG process parameters. The process parameters considered were current, wire feed rate, voltage, welding speed and nozzle to plate distance This experiment involved welding mild steel plates and the welding joint type is butt joint. The relationship between process parameter and energy is predict using Random Forest Method. The Root Mean Square Error (RMSE) and Coefficient of Determination (R² score) are used to evaluate this model. Based on this study, the most optimal process parameter influencing robotic welding machine MIG is wire feed rate. Interestingly, energy consumption in robotic welding machine MIG is less affected by welding speed. Voltage of 21 V, wire feed rate of 10 m/min, current of 140 A, welding speed of 205 mm/s, and nozzle to plate distance of 1 mm were determined to be the optimal parameter values. This study provides important insights for optimizing robotic welding machine MIG processes, increasing energy efficiency, and developing sustainable manufacturing methods.

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