Evaluation of Resistance Spot Welding Conditions Using Experimental Design
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Evaluation of Resistance Spot Welding Conditions Using Experimental Design D.Y. Medina1*, R. Bermejo1, R.T. Hernandez1, I. Hernandez1 and S. Orozco2 1 2
DCBI, UAM-A, Av. Sn Pablo 180, 02200 México D.F., México.
Fac. de Ciencias UNAM, Av. Universidad 3000, Col. Copilco el Bajo, México D.F., México. *
E-mail: [email protected]
ABSTRACT The breaking strength that can withstand solder is known as resistance welding, low resistance welding will cause a failure of the weld. This study optimized the effect of the main variables in a welding steel proceess on the mechanical propierties of the steel like the resistance welding. The main variables studied were electrode, machine, post induction, and dotted pressure. The factors that have the most influence in the resistance welding are the post induction, and the combination of post induction and the raw material.The statistical model used for the evaluation process was an analysis of variance (ANOVA) in a full crossing factorial design 2k with a second order of interaction. Keywords: steel, strength, welding, soldering, simulation.
INTRODUCTION The spot welding process is one of the most important methods in the manufacture of automotive assemblies which consist consists in a passing of a high electric current through two electrodes with tip. During the last few years, the requirements for safety and efficient materials in the design of the automotive body structure was increased and the spot welding process is an efficient response for joining process widely used for the fabrication of sheet metal assemblies which has excellent techno-economic benefits such as low cost, high speed and suitability for automation. Due to the large number of spot welds in a particular application, the process parameters need to be fine tuned. A tensile-shear strength testing is an important aspect of a weldability study, and the fracture point in the sample is knows at resistance spot welding (RSW). Many studies were investigated the mathematical optimization of factors which interview in the response in the properties of materials for a welding process in a ferrous and non ferrous[1] materials, the studies were focused in the sample size[2-5] (width, overlap, thickness and length) and in the weld (quality, size and location)[1,6-10] but there are scarce literature about the influence of the spot welding process parameters in the RSW for steel [4,6] In this study the optimal parameters as electrode, machine, post induction, dotted pressure, among others were researched. The analysis of variance (ANOVA) employed to obtain the effect of the process parameters on mechanical properties is an effect system to found a real solution [11].
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EXPERIMENTAL PROCEDURE The effects of the parameters were calculated with ANOVA in an experimental design using a matrix 2x based on the factorial design, with a second order of interaction. The process parameters and levels were shown in Table I. An experimental plan for six parameters with three levels was organized in 26 matrix. The response
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