Optimization of parameters involved in robotic MIG welding process based on quality responses

Abstract

Automation in the welding process are preferred for the enhancement of quality and time reduction. Robots are widely used for welding process in sheet metal fabrication industries. In this study, the parameters of robotic (ABB IRB 1520) Metal Inert Gas (MIG) welding process (reference voltage, wire feed rate and gas flow rate) is optimized based on the quality responses such as depth of penetration, bead width and reinforcement at welded joints in IS2062 (GRADE A) material. In order to locate optimum conditions with a relatively small number of experiments in parameter optimization, Response Surface Methodology is used. RSM is an empirical approach which uses the polynomials as local approximation to relate the true relationship between input and output. The process improvement in industrial setting is achieved by this empirical approach. The mathematical model has been deduced based on experimental data and model selection techniques. And the approach reveals the condition which favour the good balance between maximum penetration, minimum bead reinforcement and minimum bead width.