Gunaraj-10/00 Zaida

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Specifications	Gunaraj-10/00 Zaida
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Experimental Procedure The experiment was conducted at M/s. Sri Venkateswara Engineering Corp., Coimbatore, India, with the f

Specifications	Gunaraj-10/00 Zaida
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Content	Experimental Procedure The experiment was conducted at M/s. Sri Venkateswara Engineering Corp., Coimbatore, India, with the following setup. ADORE semiautomatic welding equipment with a constant-voltage, rec- tifier-type power source with a 1200-A capacity was used to join IS: 2062, struc- tural steel plates 300 x 150 x 6 mm. ESAB SA1 (E8), 3.15-mm-diameter, copper- coated electrode in coil form and ESAB- brand, basic-fluoride-type (equivalent to DIN 8557) granular flux was used. A square butt joint with a 1-mm root open- ing was selected to join the plates in the flat position, keeping the electrode posi- tive and perpendicular to the plate. Plan of Investigation The research work was carried out in the following steps (Ref. 8). • Identifying the important process- control variables. • Finding the upper and lower limits of the control variables. • Developing the design matrix. • Conducting the experiments as per the design matrix. • Recording the responses. •Developing the mathematical models. • Calculating the coefficients of the polynomials. • Checking the adequacy of the mod- els developed. • Arriving at the final mathematical models. • Conducting the conformity test. • Presenting the direct and interaction effects of different process parameters on bead geometry graphically. • Analyzing the results. Identification of the Process Variables The independently controllable process parameters affecting bead geom- etry and the quality of the weld bead were open-circuit voltage (OCV), wire feed rate (F), welding speed (S) and noz- zle-to-plate distance (N). As it was not possible to control the welding voltage (V) directly in the power source used for conducting the experiments, OCV was used as a process variable. However, V was correlated to OCV through the de- velopment of a mathematical model. Using the developed model, welding voltage (V) was calculated for all values of OCV and treated as a factor for draw- ing graphs and analyzing results. Finding the Limits of the Process Variables Trial runs were carried out by varying one of the process parameters while keeping the rest of them at constant val- ues (Ref. 9). The working range was de- cided upon by inspecting the bead for a smooth appearance without any visible defects such as surface porosity and un- dercut. The upper limit of a factor was coded as +2 and the lower limit as –2. The coded values for intermediate values were calculated from the following rela- tionship: Xi= 2[2X - (Xmax+ Xmin)] / (Xmax– Xmin), where Xiis the required coded value of a variable X; X is any value of the variable from Xminto Xmax;Xminis the lower level of the variable and Xmaxis the upper level of the variable. The process-variable levels with their units and notations are given in Table 1. Developing the Design Matrix The selected design matrix, shown in Table 2, is a five-level, four-factor, cen- tral composite rotatable factorial design (Ref. 10) consisting of 31 sets of coded conditions. It comprises a full replication of 24(=16) factorial design plus seven center points and eight star points. All welding variables at their intermediate level (0) constitute the center points, and the combinations of each of the welding variables at either its lowest (–2) or high- est (+2) with the other three variables at their intermediate level constitute the star points. Thus, the 31 experimental runs allowed the estimation of the linear, quadratic and two-way interactive ef- WELDING RESEARCH SUPPLEMENT \| 287-s RESEARCH/DEVELOPMENT/RESEARCH/DEVELOPMENT/RESEARCH/DEVELOPMENT/RESEARCH/DEVELOPMENT Fig. 1 — Cross section of a weld bead.Fig. 2 — Direct effect of welding voltage (V) on bead parameters (P, R, W, D). Table 1 — Process Control Parameters and Their Limits Limits ParametersUnitsNotation–2–10+1+2 Welding voltagevoltsV2426283032 Wire feed ratem/min.F0.700.931.161.391.62 Welding speedm/min.S0.430.510.590.670.75 Nozzle-to-platemmN30.0032.5035.037.540.0 distance
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