Mathematical Modelling to Predict Bead Geometry Parameters of MIG Welded Aluminum 6063 Plates

Abstract

The purpose of this research is to evaluate the effect of various operational parameters like voltage, weld speed, torch angle, nozzle to plate distance (NPD), and wire feed rate on bead geometry of welds on aluminum 6063 plates. This aluminum grade has a wide range of applications, from industrial to home. The bead geometry properties of a fusion weld are essential from a design standpoint because they affect the joint's mechanical strength and dependability throughout its usage. Bead width (BW), depth of penetration (DOP), and height of reinforcement (HOR) are all essential bead parameters, which need to be considered while commenting on bead geometry of a weld. An experiment series was performed with the statistical technique of design of experiments, using the central composite rotatable design (CCRD) method. This resulted in a mathematical model that correlated bead geometry parameters with various input parameters. RSM (Response Surface Methodology) is used for the graphical analysis of the results obtained. The suggested framework aims to optimize the input variables in order to attain the specified bead parameter values.

Keywords

• welding
• bead geometry
• aluminum 6063
• mathematical model
• anova
• rsm