Hybrid Taguchi method for optimizing flux cored arc weld parameters for mild steel

Abstract

Flux cored arc welding has been applied in manufacturing industries for more than fifteen years. The quality of weld mainly depends on the mechanical properties of the weld, which in turn relays on the interaction of the weld parameters. This paper discusses the multi response optimization of weld parameters using grey based Taguchi method. Grey relational analysis was carried out to convert multi objective criterion into equivalent single objective function; overall grey relational grade, which is optimized by the Taguchi technique. Experiments are conducted using Taguchi's L27 orthogonal array. The weld parameters used in this study were welding current, welding speed, and arc voltage with bead hardness and material deposition rate as responses. Taguchi's Signal-to-Noise (S/N) ratio is computed based on their performance characteristics. Grey relational grade was obtained using Signal-to-Noise ratio values of responses. Based on the grey relational grade, optimum levels of parameters have been identified. Significant contributions were estimated using Analysis of Variance (ANOVA). A confirmation test was conducted to validate the proposed method. This evaluation procedure could be used in decision-making to select process parameters for a welding operator. The proposed and developed method has good accuracy and competency with the predicted value enhancing automation and robotization.