Experimental Study an improvement of Parameters Affecting Resistance Spot Welding Strength in Halogen lamps by Taguchi Statistical Method

Subject Areas :

Lotfali Mozafari Vanani ¹ ( Lectureship, Department of Mechanical Engineering, Boroojen Branch, Technical and Vocational University, Boroojen, Chaharmahal o bakhtiari, Iran )
Sadegh Rahmati ² ( مدیر کل برنامه ریزی آموزشی و درسی دانشگاه )

Received: 2018-11-17 Accepted : 2019-06-18 Published : 2019-05-22

Keywords: Taguchi, Resistance Spot Welding (RSW), Halogen lamp, Welding Strength,

Abstract :

The Resistance Spot Welding (RSW) has lots of industrial application, especially for body construction and some parts like car lamps. The aim of this research was optimizing of the production line efficiency and improving the welding strength of the car lamps. Experimental studies were conducted on the factors affecting the weld strength in a H4 halogen lamp (wing to body connection). The experiments design and results analysis were done by Taguchi method and Minitab software. Welding current, welding time and electrode material were studied as main factors (inputs) in the actual lamp samples. Experimental results and statistical analyzes indicated that the high dependence of welding strength on welding time is primarily and with a quantitative difference in the second order to the welding current. According to the results, it was found that with any kind of electrode material, if welding time and welding current increases to moderate, welding strength will be improved. But in high values of time and current, there is a negative effect on the welding strength. Although the welding electrode has the third highest rating on weld strength. But during the testing process and analyzing it was found that the efficiency of the lamp production line in the case of using tungsten electrodes in the significant amount of 29.17% compared to the electrodes of Copper is more. While the welding strength of the tungsten electrode is only 5.5% lower than the copper electrode. This strength is still within allowed and acceptable limits of the relevant standards.

References:

 

[1]     Y. j. Chao, “Ultimate strength and failure mechanism of resistance spot weld subjected to tensile, or combined tensile/shear loads”, Journal of Engineering Materials and Technology, Vol. 125, pp. 125-133, 2003.

 

[2]     H. Ghanbari & M. Shariati, “Experimental analysis on effects of resistance spot welding parameters on the tensile tension behavior of martensite ferrite joints by taguchi statistical method”, Modares Mechanical Engineering, Vol. 17, No. 6, pp. 342-350, 2017.

 

[3]     S. Aslanlar, “The effect of nucleus size on mechanical properties in electrical resistance spot welding of sheets used in automotive industry”, Journal of Materials and Design, Vol. 27, No. 2, pp. 125-131, 2006.

 

[4]     Z. Hou, S. Kimb, Y. Wang, C. Li & C. Chena, “Finite element analysis for the mechanical features of resistance spot welding process”, Journal of Materials Processing Technology, Vol. 185, No. 1-3, pp. 160-165, 2007.

 

[5]     D. Ozyurek, “An effect of weld current and weld atmosphere on the resistance spot weld ability of 304L austenitic stainless steel”, Journal of Materials and Design, Vol. 29, No. 3, pp. 597-603, 2008.

 

[6]     B. Bouyousfi, T. Sahraoui, S. Guessasma, K. T. Chaoch, “Effect of process parameters on the physical characteristics of spot weld joint”, Journal of Materials and Design, Vol. 28, No. 2, pp. 414-419, 2007.

 

[7]     D. L. Olson, T. A. Siewert, S. Liu & G. R. Edwards, ASM Handbook, Vol. 6: Welding, Brazing, and Soldering, ASM Int., 1993.

 

[8]     T. Drozda, E. Philip, P. E. Mitchell & W. C. Charles, “Tool and manufacturing engineers handbookˮ, Society of Manufacturing Eng., 1998.

 

[9]     X. C. Wang & M. Y. Lui, “An arbitrary waveform control system for a precise spot-welding power source”, Journal of Mat. Processing Tech., Vol. 122, No. 2-3, pp. 185–188, 2002.

 

[10]  S. Aslanlar, A. Ogur, U. Ozsarac & E. Ilan, “Welding time effect on mechanical properties of automotive sheets in electrical resistance spot welding”, Journal of Mat. and Design, Vol. 29, No. 7, pp. 1427-1431, 2008.

 

[11]  H. Eisazadeh, M. Hamedi & A. Halvaee, “New parametric study of nugget size in resistance spot welding process, using finite element method”, Journal of Mat. and Design, Vol. 31, No. 1, pp. 149–157, 2010.

 

[12]  M. Oveisi, N. Banimostafa arab & G. Payeganeh, “Prediction and optimization of the diameter of the weld button in Resistance Spot welding on the sheet used in the shipbuilding industry using experimental design”, Proceedings of The 1^st  National Conference on National Development of Mokran Coasts and Islamic Republic of Iran's sea Authority, Chabahar, Iran, February 16-18, 2013.

 

[13]  National Iranian Standard, No. 6004, Lamps for road Vehicles-Performance requirements, ICS: 29.140.99, 1^st Revision, 2011.

 

[14]  Functional standard requiring the approval of supplies - PSA PEUGEOT C77 2760, 2006.

 

[15] Uniform provisions concerning the approval of filament lamps for use in approved lamp units of power-driven vehicles and of their trailers Regulation E-ECE-Regulation, No. 37, 2011.