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Taguchi approach was used for designing the experiment, L25 orthogonal
array was used which composed of five levels and 25 rows, which means that 25
experiments were carried out. Design of experiments was selected based on a four
welding parameters with five levels each. The selected welding input parameters
for this study are wire feed rate (WFR), voltage (V), travel speed (TS) and torch
angle (TA). The welding input parameters and their levels are presented in Table
I.
Table 1
Welding parameters and their levels
Parameters
Units
Torch Angle(TA)
Mm/min
volts
19
Cm/min
0
levels
3
10
11
21
23
25
27
0.3
0.36
0.42
0.48
0.54
50
60
70
80
90
The welding trails were conducted based on the L25 orthogonal array as
shown in Table III. Argon as a shielding gas at a constant flow rate of 18 lpm and
stick out distance is 15 mm as maintained. Weld profiles were obtained by
sectioning and polishing with suitable abrasive and diamond paste. Weld samples
were etched with 10% oxalic acid, an etchant to state and increase the contrast of
the fusion zone with the base metal. The weld bead profiles were measured using
optical microscope. The measured bead profiles are depth of penetration (DOP),
bead width (BW) and reinforcement(R) were presented in Table III.
Table 2
Experimental results using l25 orthogonal array
Sl.No
WFR
TS
TA
DOP
BW
mm
mm
mm
2.814
8.034
2.356
3.843
8.623
2.485
3.876
8.931
2.674
3.334
8.527
2.745
3.487
8.234
2.789
4.315
8.723
2.945
3.893
8.965
2.864
3.756
9.167
2.654
3.032
9.583
2.479
10
4.067
8.869
2.987
11
3.912
8.783
2.843
12
2.889
9.267
2.489
13
3.445
8.935
2.681
14
4.889
8.347
2.712
15
4.553
8.587
2.567
16
3.564
8.743
2.145
17
4.078
8.845
2.647
18
4.378
8.384
2.741
19
4.583
8.457
2.856
20
2.932
9.987
2.146
21
3.348
9.267
2.216
22
4.392
8.932
2.347
23
3.641
9.124
2.045
24
3.994
9.256
2.249
25
3.826
9.016
2.198
S/N Ratios
Normalized values
DOP
BW
DOP
BW
8.9865
-18.0986
-7.4435
0.0000
0.0000
0.3737
11.6934
-18.7132
-7.9065
0.5642
0.3251
0.5144
11.7677
-19.0180
-8.5432
0.5797
0.4864
0.7078
10.4593
-18.6159
-8.7708
0.3070
0.2737
0.7770
10.8490
-18.3122
-8.9090
0.3882
0.1130
0.8190
12.6996
-18.8133
-9.3817
0.7739
0.3781
0.9626
11.8057
-19.0510
-9.1395
0.5876
0.5039
0.8890
11.4945
-19.2445
-8.4780
0.5227
0.6063
0.6880
9.6346
-19.6300
-7.8855
0.1351
0.8102
0.5080
10
12.1855
-18.9575
-9.5047
0.6667
0.4544
1.0000
11
11.8480
-18.8729
-9.0755
0.5964
0.4096
0.8696
12
9.2150
-19.3388
-7.9205
0.0476
0.6561
0.5186
13
10.7438
-19.0219
-8.5659
0.3663
0.4885
0.7147
14
13.7844
-18.4306
-8.6658
1.0000
0.1756
0.7451
15
13.1660
-18.6768
-8.1885
0.8711
0.3059
0.6000
16
11.0388
-18.8332
-6.6285
0.4277
0.3886
0.1260
17
12.2089
-18.9340
-8.4551
0.6716
0.4420
0.6810
18
12.8255
-18.4690
-8.7582
0.8001
0.1960
0.7732
19
13.2230
-18.5443
-9.1152
0.4714
0.2358
0.8816
20
9.3433
-19.9887
-6.6326
0.0744
1.0000
0.1272
21
10.4957
-19.3388
-6.9114
0.3146
0.6561
0.2120
22
12.8532
-19.0190
-7.4103
0.8059
0.4869
0.3636
23
11.2244
-19.2037
-6.2139
0.4664
0.5847
0.0000
24
12.0282
-19.3285
-7.0398
0.6340
0.6507
0.2510
25
11.6549
-19.1003
-6.8406
0.5562
0.5300
0.1904
Step 3: Perform the grey relational analysis. From the data in Table 4, calculate the
grey relational co-efficient for the normalized S/N ratio values by using (5). The
values for is taken as for depth of penetration (0.5), bead width (0.25) and
reinforcement (0.25) and were considered in (4). The results are given in Table V.
Step 4: Next, the grey relational grade can be computed by using (6). Finally, the
grades are considered for optimizing the multi response parameter design problem.
Voltage
0.0189
0.0047
3.9692
3.8379
%
Contribu
tion
F-table
F-Cal
0.0534
squares
Mean
Wire
feed rate
Factor
Squares
ofDegree
freedom
Sum of
(14.0232%).
27.6792
9.7974
Travel
speed
0.0451
0.0113
3.8379
23.3601
Torch
angle
0.0661
34.2267
Error
0.0095
0.0012
Total
0.1930 24
9.4638
4.9367