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Optimization and modeling of spot welding parameters with simultaneous multiple response consideration using multi-objective Taguchi method and RSM

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Abstract

This paper presents an alternative method to optimize process parameters of resistance spot welding (RSW) towards weld zone development. The optimization approach attempts to consider simultaneously the multiple quality characteristics, namely weld nugget and heat affected zone (HAZ), using multi-objective Taguchi method (MTM). The experimental study was conducted for plate thickness of 1.5 mm under different welding current, weld time and hold time. The optimum welding parameters were investigated using the Taguchi method with L9 orthogonal array. The optimum value was analyzed by means of MTM, which involved the calculation of total normalized quality loss (TNQL) and multi signal to noise ratio (MSNR). A significant level of the welding parameters was further obtained by using analysis of variance (ANOVA). Furthermore, the first order model for predicting the weld zone development is derived by using response surface methodology (RSM). Based on the experimental confirmation test, the proposed method can be effectively applied to estimate the size of weld zone, which can be used to enhance and optimized the welding performance in RSW or other application.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM), 40450, Shah Alam, Selangor, Malaysia

    Norasiah Muhammad, Yupiter H. P. Manurung, Mohammad Hafidzi, Sunhaji Kiyai Abas, Ghalib Tham & Esa Haruman

  2. Bakrie University, Jakarta, Indonesia

    Esa Haruman

Authors
  1. Norasiah Muhammad
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  2. Yupiter H. P. Manurung
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  3. Mohammad Hafidzi
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  4. Sunhaji Kiyai Abas
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  5. Ghalib Tham
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  6. Esa Haruman
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Corresponding author

Correspondence to Yupiter H. P. Manurung.

Additional information

Recommended by Associate Editor Vikas Tomar

Yupiter HP Manurung is currently an Associate Professor at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his BSc. in Manufacturing Technology from University of Applied Sciences GSO Nueremberg, Germany and his MSc. as well as Ph.D in Manufacturing Technology from University O-v-G Magdeburg, Germany. He also obtained International/European/German Welding Engineer (IWE/EWE/SFI) from SLV Halle, Germany and Laser Technology from University Jena, Germany. His research interests include Advanced Manufacturing Technology and Simulation, Advanced Welding Technology and Simulation and Quality & Reliability Engineering.

Norasiah Muhammad is currently a Ph.D student in Mechanical Engineering at the Universiti Teknologi MARA (UiTM) Malaysia. She received her BSc. in Material Engineering in 2000 and MSc. in Material Engineering in 2001 from Universiti Sains Malaysia (USM).

Esa Haruman is currently a lecturer at Bakrie University, Jakarta, Indonesia. He was formerly Associate Professor at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his BSc. in Material Science and Metallurgy from University of Indonesia and his MSc. and Ph.D in Metallurgical Manufacturing from University of Birmingham UK. His research interests include Advanced Materials, Manufacturing Process, Heat Treatment and Surface Engineering.

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Muhammad, N., Manurung, Y.H.P., Hafidzi, M. et al. Optimization and modeling of spot welding parameters with simultaneous multiple response consideration using multi-objective Taguchi method and RSM. J Mech Sci Technol 26, 2365–2370 (2012). https://doi.org/10.1007/s12206-012-0618-x

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  • DOI: https://doi.org/10.1007/s12206-012-0618-x

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