A

DISSERTATION ON
“OPTIMIZATION OF PROCESS PARAMETERS OF
MIG WELDING FOR TENSILE STRENGTH AND
SURFACE ROUGHNESS”
SUBMITTED
INPARTIALFULFILLMENT OFTHE REQUIREMENT FOR THEDEGREE OF

MASTEROFTECHNOLOGY
IN
MECHANICALENGINEERING
(SPECIALIZATION: MECHANICAL)
By
Ajit kumar verma
Enrollment No: -
Under the Supervision of

DR. A.P.J. ABDUL KALAM TECHNICAL

UNIVERSITY, UTTAR PRADESH, LUCKNOW, INDIA
JUNE2019
DEPARTMENT OF MECHANICAL ENGINEERING
GOEL INSTITUTE OF TECHNOLOGY& MANAGEMENT
LUCKNOW

i
 CERTIFICATE

This is to certify that the thesis work entitled “OPTIMIZATION OF

PROCESS PARAMETERS OF MIG WELDING FOR TENSILE

STRENGTH AND SURFACE ROUGHNESS” submitted by Ajit Kumar

Verma, Roll No. 1736040503in partial fulfillment for the award of Master of

Technology degree in Mechanical Engineering Department with

specialization inMechanical Engineering, to Goel institute of technology &

management, Lucknow (U.P.), India Affiliated to Dr.A.P.J.AbdulKalam

Technical University, Lucknow. He has carried out his thesis work under my

supervision and guidance and to the best of my knowledge; the matter

embodied in this thesis has not been submitted to any other University/Institute

for award of any degree to the candidate or to anybody else.

Date:
(Assistant Professor)
Department of Mechanical
Engineering
Goel institute of technology &management, Lucknow

ii
 CANDIDATE’S DECLARATION

I hereby declare that the work which is being presented in the thesis entitled
“Optimization of Process Parameters of MIG Welding For Tensile Strength and
Surface Roughness”, submitted to the Department of Mechanical Engineering, to
Goel institute of technology & management, Lucknow (U.P.), affiliated to
Dr.A.P.J.AbdulKalamTechnical University, Lucknow for award of degree of Master
of Technology in Mechanical Engineering, is an authentic record of my own work
carried out during my M.Tech course under the supervision of Er……………….
I have not submitted the matter presented in the thesis for the award of any other
degree of this or any other university.

Date: 15/06/2019 Ajit Kumar verma

Lucknow

iii
 ABSTRACT

Many researchers have been performed in the area of welding and the
technology is advancing day by day. MIG welding is a technique of joining to metal
pieces in an inert gas environment using a wire electrode constantly fed for
producing arc and acts as filler metal for the weld pool. Almost all the metals can be
easily welded by MIG welding process from copper to aluminum, low carbon steels
and other alloy steels. The present investigation for optimization of MIG welding
of Mild Steel is conducted to establish the influence of MIG welding process
parameters on tensile strength and surface roughness. From the experimental results
it is concluded that welding voltage is the maininfluencing parameter for tensile
strength while welding speed is least influencing for it. For the case of surface
roughness, welding speed has major dominance while other parameters were less
effective.

iv
 ACKNOWLEDGEMENT

Iwouldliketoexpressmy deepsenseofgratitudeandrespect tomy

supervisor guide name for his invaluable guidance,motivation,constant
inspiration and above all for his Verso-operating attitude that enable
bringingup this thesisinthepresentform. Iconsidermyselfextremely lucky to be
abletoworkundertheguidance of ----------------- personality.
I am also thankful to Head of Department, Mechanical Engineering, for
his support and motivation.

I would also like to thank to “Punjab Body Builders”, Sarojini Nagar

Industrial Area, Lucknow who provided meMIG welding machinefor
successful completion of experimental work.

My very specialthanksgotoallmy familymembers.Theirlove affection and

tolerance madethisworkpossibleandthefavorandencouragementofmy
belovedparentsgreatlyhelpedme in carryingoutthisresearchwork.

Place: Lucknow Ajit kumar verma

Date:

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 TABLE OF CONTENTS

CERTIFICATE ii
ABSTRACT iv
ACKNOWLEDGEMENT v
LIST OF TABLES viii
LIST OF FIGURES x

CHAPTER1: INTRODUCTION 1-11

1.1 Introductionand Principle 1
1.2 Arc Welding 3
1.2.1 MIG Welding 4
1.3 Welding Structure 5
1.4The Power Source 6
1.5Welding Technique 7
1.6Welding Condition 8
1.7 Welding Quality Assurance 9
1.8 Joint Design 10
1.9Specific Recommendation of low carbon MS 10

CHAPTER2: LITRETURE REVIEW 12-16

2.1 Literature Review 12
2.2 Problem Formulation 16

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CHAPTER 3: TAGUCHI APPROCH AND ANOVA 17-24
3.1 Taguchi experimental design 17
3.2 Design of Experiment 17
3.3 S/N ratio 20
3.4 Process of Taguchi Method 21
3.5 Application of S/N ratio 21
3.6 Advantages of S/N ratio over average 22
3.7 Role of ANOVA 22
3.8Analysis of variance 23
3.9Table for Taguchi Design of experiments 24

CHAPTER 4: EXPERIMENTATION 25-34

4.1 Experiment setup 25
4.2 Work piece material 28
4.3Surface Roughness 33
4.4Tensile Testing 34

CHAPTER 5: RESULTS AND DISCUSSION 40-49

5.1 Calculation for Tensile Strength 40
5.1.1 Calculation of S/N ratio for Tensile Strength 40
5.1.2 Calculation of Mean S/N ratio for Tensile Strength 40
5.1.3 ANOVA for Tensile Strength 42
5.2 Calculation for Surface Roughness 46
5.1.1 Calculation of S/N ratio for Surface Roughness 47
5.1.2 Calculation of Mean S/N ratio for Surface Roughness 48
5.1.3 ANOVA for Surface Roughness 49

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5.3 Confirmation Test 52

CHAPTER 6: CONCLUSION 53-49

6.1 Conclusion 48

REFERENCES 54-56

viii
 LIST OF TABLES

CHAPTER 3
Table-3.1 Array Selector.
Table-3.2 Levels of process parameters for orthogonal Array.
Table-3.3 Table for Taguchi design of experiment.
Table-3.4Experiment L9 orthogonal Array.

CHAPTER 4
Table-4.1 Technical specification of Migmatic 250
Table-4.2 Properties of Mild Steel
Table 4.3 Chemical composition of Work-piece (Mild Steel) by weight

CHAPTER 5
Table-5.1 Calculation for Tensile Strength
Table-5.2 Calculation of S/N ratio for Tensile Strength
Table-5.3 Calculation of mean S/N ratio for Tensile Strength
Table-5.4 ANOVA of Tensile Strength
Table 5.5 Values of MRR corresponding to different levels of Welding Voltage
Table-5.6 Calculation for Surface Roughness
Table-5.7 Calculation of S/N ratio for Surface Roughness.
Table-5.8 Calculation of Mean S/N ratio for Surface Roughness.
Table-5.9 ANOVA of Surface Roughness.
Table-5.10 Confirmation of expected and actual values of Tensile Strength.
Table-5.11 Confirmation of expected and actual values of Surface Roughness.

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 LIST OF FIGURES

CHAPTER 1
Figure 1.1MIG welding
Figure 1.2 Set up MIG welding

CHAPTER 4
Figure 4.1 ESAB Migmatic 250 Welding machine
Figure 4.2 Welding of specimen on MIG machine
Figure 4.3 Migmatic 250 machine panel
Figure 4.4 Mild Steel welded Work pieces
Figure 4.5 MS flat bars
Figure 4.6Grinding of MS specimen
Figure 4.7Semi-finished MS specimen
Figure 4.8Finishing of MS specimen
Figure 4.9 Mitutoyo SJ 400 surface roughness tester
Figure 4.10 UTM machine
Figure 4.11 Specimen before loading on UTM
Figure 4.12 Specimen after breaking on UTM

CHAPTER 5
Figure 5.1: Main effect plot for Tensile Strength
Figure 5.2: Interaction plot for Tensile Strength
Figure 5.3: Contribution of parameters for Surface Roughness
Figure 5.4: Main effect plot for Surface Roughness

x
 CHAPTER 1

INTRODUCTION

1.1Introduction and Principle

Throughout the World, welding is major fabrication technology that is used extensively for
construction of structures, buildings and bridges and in the civil, automotive, aircraft, aerospace,
petroleum, shipbuilding, and electronic industries. Althoughwelding is an addition technique, it is
seen by much primitive science. During last several years, it has advanced as an interdisciplinary
action that requires synthesis of knowledge from different disciplines and incorporates the most
advanced equipments of various basic engineering and applied sciences. Researchers from
different disciplines such as arc and plasma physics, thermodynamics materials science,
manufacturing, transport phenomena, modeling, robotics, economics, and fromvarious
engineering fields that includes mechanical, chemical, and electrical engineering are currently
making new innovations. Considering some major industries, notably automobile, welding is
performed primarily by the help of robots or automated assemblies. Moreover, in other industries
like shipbuilding wheresubstantial hardware creation and little parts manufacture is done, welding
is largely done by a manual process done by human operators. Skill training of fresh welders is an
important activity both for industries and for the vocational institutions. Training is majorly
important for welders who are working on critical items like pressure vessels, naval ships, etc
where welding requires carefully inspection. Welding is joining process which has its own
advantages and drawbacks. The most obvious advantage is that: Welding is usually the most
economical way of joining components in terms of material usage and fabrication costs. Alternative
mechanical methods of assembly require more complex shape description (for example drilling of
holes and addition of fasteners for example rivets and bolts). The resulting mechanical assembly is
usually heavier than the corresponding weldment. Few draw backs of welding are that most of the
welding operations are performed manually and are generally expensive due to labor cost; many
welding operations are considered for skilled trades. Most welding processes, involving the use of

1
high energy, are inherently dangerous and the welded joint can suffer from certain quality defects that
reduce the strength of the joint.

Steel parts have are now replaced with aluminum alloys in many industries as their lightweight,
easy fabrication and machinability, good corrosion resistance and other superior properties are
achieved as compared to steel and other metals.

Considering the joining procedure for those mechanical fields, welding is the most appropriate
and simple application technique. At the point when the welding of steel combinations are
considered, the expenses are assuming a fundamental job, henceforth, gas tungsten circular
segment welding or TIG and gas metal bend welding or MIG systems are significantly utilized.
GMAW strategy, which metal dormant gas welding (MIG) is the subsystem, is the most cost
effective technique utilized in businesses. Subsequently for a large portion of the applications,
MIG welding is utilized for joining steel compounds. In spite of the fact that it joins a few
deformities during MIG welding, for example, porosities, hot splitting thus, related with certain
properties of especially heat treatable gentle steels, these can be diminished by controlling
welding parameters and picking right filler materials. Albeit because of the idea of welding,
quality misfortune can be seen in the wake of welding. Subsequent to welding, the fundamental
quality misfortune is seen in the warmth influenced zone and in region. The quality at any rate in
tempered state of metal can be sufficient in the wake of welding, scarcely, the spots of utilization
are not generally permit this circumstance.

2
 Considering the joining procedure for those mechanical fields, welding is the most
appropriate and simple application technique. At the point when the welding of steel
combinations are considered, the expenses are assuming a fundamental job, henceforth, gas
tungsten circular segment welding or TIG and gas metal bend welding or MIG systems are
significantly utilized. GMAW strategy, which metal dormant gas welding (MIG) is the
subsystem, is the most cost effective technique utilized in businesses. Subsequently for a
large portion of the applications, MIG welding is utilized for joining steel compounds. In
spite of the fact that it joins a few deformities during MIG welding, for example, porosities,
hot splitting thus, related with certain properties of especially heat treatable gentle steels,
these can be diminished by controlling welding parameters and picking right filler materials.
Albeit because of the idea of welding, quality misfortune can be seen in the wake of
welding. Subsequent to welding, the fundamental quality misfortune is seen in the warmth
influenced zone and in region. The quality at any rate in tempered state of metal can be
sufficient in the wake of welding, scarcely, the spots of utilization are not generally permit
this circumstance.

1.2. Arc Welding

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Arc welding procedure is a procedure of welding with a development arc between a cathode pole
and the metal workpiece by warming of workpiece metal and causing to soften filler metal with
base metal together and the joint between them is made. This technique was at first created by
aluminum and aluminum composites however thereafter it is additionally utilized for steels. In
this investigation a subtype of bend welding strategy called Metal Inert Gas (MIG) welding will
be utilized for welding of gentle steel.

1.2.1. Metal Inert Gas Welding (MIG)

Metal-inert gas welding (MIG) is a process of joining metals by melting with the heat generated by arc
established between a continuously fed filler wire electrode through the wire reel and the metal
workpiece that can be seen in Figure 1.1

Figure 1.1 MIG welding: (a) overall process (b) welding area enlarged

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The liquid weld puddle and the arc zone are protected by inactive gases mode of argon or helium
or carbon dioxide. Metal idle gas (MIG) is otherwise called Gas Metal Arc Welding (GMAW)
and this strategy is the most widely recognized procedure utilized for gentle steels and a smooth
metal exchange is seen with low scatter misfortune and great weld infiltrations can be
accomplished by a steady curve.

Considering the shielding gases, argon, helium or carbon dioxide and their mixtures are used for
ferrous and nonferrous metals as well as stainless and alloy steels. Although comparing the arc
energies for argon arc, this energy is less uniformly dispersed as compared to helium arc as the lower
heat conductivity of argon gas. Hence as a result of this phenomenon, argon arc plasma generally has
a very high energy core and it is observed that an outer mantle of lesser thermal energy is seen and by
this, a stable, axial transfer of metal droplets through argon arc plasma can be achieved.

1.3. Weld Structure

During the way toward welding, when the arc is made, heat is created in a weld pool and a few
locales of the base metal are straightforwardly influenced by this warmth age and some different
districts are not influenced. With this regard, there are three noteworthy locales in the weldment
region that can be effectively recognized either with unaided eye or made noticeable with the
assistance of compound drawing. The three weldment locales are called as the Weld Metal,
Partially Melted Zone and the Heat Affected Zone (HAZ). Other than these three fundamental
districts, the rest of the piece of the metal can be called as parent metal or base metal which is
leastinfluenced by warmth produced during welding.

Weld Metal is area which is totally softened and cemented by the cathode, along these lines
comprises of base metal just as the filler materials. When we increment the quantity of weld
passes, the substance thesis of the weld metal achieves the concoction structure of the filler metal.
The limit that parts the weld metal and the base metal is knownas the combination line (FL) where
the temperature of weld metal reaches the liquid us temperature. The locale which is influenced
by the warmth advanced by welding process and is between the weld metal and base metal is
known as Heat Affected Zone (HAZ). This district begins from combination line and finishes at
the point where solidus temperature is achieved which is known as the Partially Melted Zone

5
(PMZ) where the warmth is excessively low to totally soften extreme it is sufficiently high to
change the microstructure.

1.3.1. Heat Affected Zone (HAZ)

Heat Affected Zone (HAZ) is the district found between incompletely liquefied zone and the base
metal. Subsequently, it is influenced by the high temperatures produced during welding however
no dissolving happens crosswise over HAZ. In any case, because of the warmth input, the base
metal microstructure is changed and recently increased great mechanical properties are influenced
in a turnarounddirection. Along these lines, to recoup the mechanical properties in HAZ, post
weld heat medications are completed.

Figure 1.2 Setup of MIG welding for the experiments

1.4 The Power Source

The immediate current with steady potential power sources are utilized for most MIG welding
forms. This stands out from TIG and stick cathode welding which uses the consistent current
power source. A MIG power source gives are steady measure of voltage during the procedure to
the bend. This voltage additionally decides the length of the curve. At the point when there is an
abrupt change in welding parameters, or a flashing change in bend length, the power source

6
progressively increments or diminishes the current relying upon the adjustment in curve
length .The consume off rate of wire changes itself in order to reestablish the first length of the
circular segment. Accordingly, lasting changes long of circular segment are seen by modifying the
yield voltage of the power source. The wire-feed speed chosen by the administrator preceding
welding, decides the bend current. It tends to be effectively changed over an extensive scale
before the bend length changes a lot to cause stubbing to the work piece or may cause the
consuming back to the guide tube.

1.4.1 Power Source Variables

The Arc length must act naturally adjusting with the consistent voltage welding framework is
alluring for delivering stable welding conditions. Explicit electrical parameters are required to
control the warmth of circular segment, splash because of welding, and so forth. These electrical
attributes incorporate voltage, incline, and inductance.

1.4.2 Voltage

It is the voltage over the finish of the wire and the workpiece. As voltage drops are experienced in
the welding forms, subsequently the arc voltage is hard to be legitimately perused on the power
source voltmeter. Welding voltage has a significant impact on the sort of procedure variety or on
the method of metal exchange. Short circular segment welding wants generally lower voltages
while the splash bend needs higher voltages. It must be accounted that, as well, with increment in
welding current and wire consume off, the welding voltage should likewise been upgraded some
as to look after security.

1.5Welding Techniques

At first, the general welding strategy that impacts the weld qualities is position of light. This by
and large alludes to the method with which the light is held as for the weld joint. The position is
essentially described from two heading; they are the point with respect to the weld length and the
edge in respect to the plates. The back hand technique by and large demonstrates that the light is
situated with the end goal that the wire is encouraging inverse way to that of circular segment
travel. The filler metal is being sustained straightforwardly into the weld pool recently saved. In

7
the forehand system, the light is somewhat calculated with the end goal that the cathode wire is
nourished toward the path same as that of circular segment travel. Besides the filler metal is
saved, generally, straightforwardly on the weld score of workpiece. It ought to be viewed as that
an adjustment in course of welding isn't required to encourage forehand or strike welding,
however just an inversion in the longitudinal light situating. Fundamentally the administrator
finds that the strike method gives a progressively steady curve with lesser splash on the
workpiece.

1.6Welding Conditions
The welding conditions ought to be viewed as just as a beginning stage with new applications. It
does not speak to the main course where a specific weld should be possible. Changing the welding
conditions will prompt circumstances brought about by contrasts in the welder's aptitudes and
experience, the joint plan and the gear which are utilized. In order to accomplish the ideal
dimension of welding conditions that satisfies the specific necessities of a more up to date work, it
is constantly alluring to perform qualifying tests before the creation. In spite of the fact that, this is
the only an essential point for set a decent, stable welding condition and it very well may be for
the most part be utilized for some applications. At the point when there are changes in the welding
conditions are required, they should be made cautiously inorder to accomplish better outcomes.
Every one of the changes must be performed each one in turn and the prominent for future
reference. The standards ought to be fixed to paying little respect to the welding system at long
last picked. Each table records all the essential circumstances to make a weld, in view of the
thickness of material, plan of joints, and welding position. When alluding these tables, there are
not many significant focuses as beneath:
1.The voltage listed is the arc voltage and not the voltage read from voltmeter. The arc voltage is
measuredbetween the final point of electrical contact in the torch and the workpiece. It is notthe
voltage shown on the voltmeter that is generally 1.5 to 2.5 volts more depends on thesize and
length of power cable.
2. The weld size must be equivalent to the material thickness for filet welds.
3. The joint structures indicated are by all account not the only plans which could be utilized for a
given material thickness.

8
4. These tables are based on tip-to-work separation of 3/8 in. (9.4 mm) for shorter circular
segment welding and 3/4 in.(19.2 mm) for splash curve welding.
5. The vertical welding methods are essentially intended for vertical up movement.

6. The welding conditions were utilized explicit protecting gases. In the event that the protecting
gases utilized are not comparable, slight alterations must be made for these conditions. Talking
about welding conditions, a consume off graph for each wire terminal is appeared. With these
diagrams, the wire-feed speed for any esteem current might be determined.

1.7Weld Quality Assurance

Independent of the material that is to be welded, there are some basic precautions which must be
undertaken so as to avoidporosity in the weld and to eliminate lack-of-fusion defects.
1. The material to be welded must be as clean and all grease, oil, and other lubricants must
beremoved. For obtaining best quality welds, all scales, rust and other oxide coverings the work
surface must be removed either mechanically orchemically. This is required while welding mild
steel.
2. During the welding of carbon steel plate, only use the shielding gas and wire combinations are
recommended for the specific variety of steel in use.
3. Basicallyavoid welding conditions that result in the very rapid weld bead solidification, like
very high travel speeds. Porosity is caused when the gas which normally be evolved from the
weld metal during slower cooling is trapped.
4.To maintain an adequate amount of shielding gas flow and to protect the welding area from
wind and drafts.
5. Keeping the welding wire centered with the shielding gas pattern. Wire curvature is generally
the main reason for thewire being off center. This can be avoided by using a wire straighter
directly on the wire feeder.
6. During welding from both sides of a sheet and for those part where there has been no
penetration of the first weldentirely through the material, confirm that the second pass must
deeply penetrates the first pass. Inspect for the first passthat it has entirely penetrated, or where a
root gap is used; grind the back side to goodweld metal before the second weld pass is performed.
This is compulsory when quality welds are required in mild steels, carbon and stainless steel.

9
7. Avoiding welding conditions that leads to the molten weld metal rolling out in front of the arc.
This is the majorreason for lack-of-fusion defects, andin particular, downhill welding.
8. During multipass welding, grinding to a flat surface all weld beads must be done which appear
to be peaked and exhibit poor welding.
9. Remove all the small patches of oxide slag found on the surface of weld bead with a file or
screwdriver when another welding to be made over it.

1.8Joint Design
There are a couple of general practices that are considered while structuring the weld joints. Plate
3/16 inch, (4.8mm) thick or less considers be butt welded with square edges utilizing the short
curve process or rather a low current shower circular segment (gentle steel) when a root hole of 0
to 1/32 inch is kept up. For all cases, a solitary pass can be utilized when a perpetual or
impermanent reinforcement bar is connected. During the welding in the overhead position, the
training for the most part is to dependably butt weld with a reinforcement bar. Despite the fact
that, if a reinforcement bar of any sort isn't used for 1/8 inch thick plate or more, it requires two
passes typically one from each side. A dab should cover more prominent than the first root hole to
avoid porosity in centerline and poor combination. To achieve most extreme cover the back hand
method is utilized on the second side. Plates having 1/4 inch thickness and thicker are by and
large made single or twofold Vee grooves with 45° to 70° included edges dependent on base
material and thickness in order to deliver quality welds.

1.10 Specific Recommendations for Low Carbon Mild Steel

 Short arc segment welding ought to be utilized while welding slight materials in the
level position
 Either CO2 or Ar-CO2 mixtures must be used for arc stability, weld bead shape,
minimalspatters thus resulting in better mechanical properties of the weld.
 While if there should be an occurrence of splash bend welding, Ar-O2 and Ar-CO2
blends might be utilized. Shower circular segment welding must be utilized in the
level position for single pass or multi-pass welding while utilized for thicker material.

10
 For low flows, vertical welds should be possible utilizing a declining bend travel.
They can utilize either strike or forehand welding strategy for welding in the level
position with no acclimations to the conditions. Fundamentally, the forehand system
gives better perceive ability to the welder of the weld joint and a compliment weld
puddle. While if there should arise an occurrence of strike strategy, it yields better
infiltration and is a few times seen to be simpler by the unpracticed welder.
 Moreover, the vertical up and the vertical down system can likewise be utilized,
however are not conversely. The movement rates of vertical down welding are
considerably more than that of vertical up. Vertical down is typically utilized for
welding slim areas (up to 1/4 inch thick) where speed is significant. Vertical up
welding is favored for welding thicker material areas where quality and quality are
fundamental prerequisites.

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 2

LITERATURE REVIEW

2.1 LITERATURE REVIEW

Major studies have been under research by various researchers in the domain of welding
technology. The researchers have performed investigations giving depth knowledge and insight
knowledge of present welding technology. This investigation aims to improve weld joint tensile
strength and surface finish using Taguchi technique. Relevant literature surveys on MIG welding
have been performed and the inspiration of the findings by the various previous researches are
presented and discussed in this chapter.

Sindiri Mahesh and Velamala.Appalaraju[1]through their experimentations inferred that

with increment in the dimensions of the chose parameters for MIG welding of AISI 1050, the
quality of welded joint is upgraded and all the chose parameters have sway on the quality of
the joint.

Sapakalet al [2] displayed the impact of welding parameters like welding current,
welding voltage, welding speed on entrance profundity of MS C20 material during
welding. An arrangement of investigations dependent on Taguchi system has been
utilized to procure the information. An Orthogonal exhibit, sign to clamor (S/N)
proportion and examination of difference (ANOVA) are utilized to research the
welding qualities of MS C20 material and advance the welding parameters. At last the
adaptations tests have been completed to contrast the predicated qualities and the trial
esteems affirm its adequacy in the examination of entrance.

12
ManojSingla et al[3] by their study concluded that the Welding current was found to be most
influencing variable to WDA. When a constant heat input is provided, and the welds are made
using electrode negative polarity having a small diameter electrode and low voltage with low
welding speed, it produce large bead area. Most effective design was found for two level
fractional half area fractional designs to quantify to main and interaction influences of variable
on the weld bead area.

Pushpendra Kumar Sharma et al [4]through their examination found that the Tensile
quality of weld increment in extent to the weld dab width, as a result of the higher MIG
parameters we watch more extensive weld head during the development weld dab hardness.
Hardness esteems are comparative in them two

Biswajit Das, B. Debbarma et al [5].through their research concluded that the higher voltage (>
26.5 V) causes abrupt rise in penetration depth value, whereas very high current (> 150 A) also
causes the same. Very high welding speed (> 0.16 m/min) cause a decreasein penetration depth.

H.J. Park et al. [6]through their investigation for optimizing the wire feed speed against the
welding speed while performing MIG lap joint fillet weld of 1.6 mm on aluminum alloy. The
experiments were carried with various wire feed speeds and the bead characteristics were
evaluated. The wire feed speed was basically optimized for various welding speeds in there
research.VikasChauhanet al. [7].carried an investigation for studying the dissimilar metal
plates joined by MIG welding. Current, voltage and travel speed were chosen for the analysis.
Taguchi technique was used to plan the experiment design to acquire the data. The influence
of each factor was examined by using the ANOV.S.Sivakumaret al.[8]through their study
investigated the influence of different factors on welding penetration, micro structural and
measurement of hardness for mild steel of 6mm thickness by using MIG welding.

K. Abbasi[9].in their examination found that when speed is taken as factor parameters,
entrance profundity increments with increment in speed upto an ideal estimation of 1450
mm/min, past that speed infiltration begins diminishing. These scientists additionally
discovered that when the warmth info is considered, the profundity of infiltration will

13
increment with warmth contribution till 109 J/min. Past this worth, the infiltration profundity
will diminish.

Patilet al. [10]during the examination while finding the impact of welding current, welding
voltage, welding on a definitive rigidity (UTS) of AISI 1030 mellow steel material during
welding procedure utilized Taguchi strategy for structuring the investigations and
investigation of difference was utilized for contemplating the welding attributes of material
and enhance the welding parameter.

ChandreshN.Patel et al. [11]in the investigation of plan of test strategies received the dim
social examination (GRA) enhancement system, where the information parameters for MIG
welding chose were welding current, wire width and wire feed rate and the exhibition measure
was hardness. Another examination conveyed byAjitHoodaet al. [12],they built up a RSM
modelfor foreseeing rigidity of dormant gas metal MIG welded AISI 1040 medium carbon
steel. Welding voltage, current, and wire speed and gas stream rate were picked as the
parameters of the machine. RSM system was connected for upgrading the MIG welding
process parameters to achieve the most extreme yield quality of the joint. S.Utkarshet al.
[13]in their investigation studied the influence of input parameter such as welding current,
welding voltage, gas flow rate in l/min and welding speed in m/min so as to study the Ultimate
Tensile Strength(UTS) of st-37 low alloy steel material in MIG Welding
(GMAW).Experiments were carried out by using L9 orthogonal array.SudeshVermaet al.
[14]investigated the enhancement of info parameters of metal inactive gas welding by utilizing
Taguchi Method of trial structure forbead width and globule tallness. They found that every
parameter has effect on the yield parameters.

SrivaniValluru et al[15]in their examination uncovers that Weld Area Hardness is a lot
higher than parent metal hardness and not as much as Heat influenced zone Hardness.

14
Kanwalet al. [16] researched for enhancement of MIG welding parameters for Hardness utilizing
Taguchi technique. Welding rate, current and voltage were taken as welding parameters.
Aluminum compounds of evaluations 6061 and 5083 were the materials mulled over for their
investigation.Amit Pal et al. [17]in their examination demonstrated the impact of welding
voltage, filler wire rate and v-butt plot for the quality of weld joint and the stretching got during
the elastic test. Every one of these parameters don't have comparable impact on welding quality.
Taguchi Orthogonal cluster has been utilized to enhance the weld nature of medium carbon steel.
The ANOVA was performed to anticipate the rate impact of each factor on results.Jay Joshi et al.
[18]conveyed the examination of structure of trial technique for the trial information for
streamlining by the dim social investigation strategy. For the examination the info parameters for
MIG welding chose were welding current, gas stream and wire feed rate while the yield parameter
chose was elasticity.B. Mishra et al.[19]introduced the impact of welding current, welding
voltage, welding speed for the entrance profundity of AISI 1020 steel while MIG welding.
Taguchi technique has been utilized to design the variety of examinations. The information was
procured and advanced for different welding parameters and for the procedure. At long last they
led the adaptations tests for getting the contrast between the real and predicated values to look at
the viability during the investigation of infiltration.NurAzhaniAbdRazaket al. [20]through their
exploration introduced the erosion conduct of low carbon steel while MIG welding at different
welding voltages and filler materials. Butt joint were made on the examples utilizing the metal
idle gas (MIG) process with welding voltage running between 19 to 21 V having 1 V interim, and
the filler materials considered for the investigation were ER 308L and ER 70S-6 with 1.2 mm
width.Pranesh B. Bamankaretal [21]contemplated the impact of MIG welding parameters on
profundity of infiltration and globule width. They attempted examinations utilizing welding
current, circular segment voltage and welding speed for mellow steel with 12 mm thick plate for
contemplating the impact of these parameters on entrance profundity. Taguchi technique for
structure of trials was utilized and L9 symmetrical cluster was chosen thinking about three
elements and three dimensions.

15
2.2 PROBLEM FORMULATION
On the basis of above literature surveythe parameters selected for this thesis work arc welding
voltage, welding current and welding speed so as to analyze the tensile strength and surface
roughness using Taguchi L9 orthogonal array

i. To investigate and analyze parameter in MIG welding for tensile strength

ii. To investigate and analyze parameter in MIG welding for surface roughness

16
 3

TAGUCHI APPROACH AND ANOVA

3.1TAGUCHI EXPERIMENTAL DESIGN

The Taguchi method incorporates the reducing of the variation in a process by robust design
of experiments. The main objective of this method is to achieve high quality product at a
lower cost to production. This Taguchi method was found a researcher called Genichi
Taguchi. He developed this method for designing the experiments for investigating how
different factors influence the mean and variance of a process performance measure that
defines how good the process is functioning. This experimental design which was proposed
by Taguchi involves the use of orthogonal arrays for organizing the parameters affecting the
process and the optimum levels at which they should be varied. Instead of testing all
possible combinations like that in the case of the factorial design, the Taguchi method only
tests a pairs of combinations. This will allow the collection of the necessary data for
determine what factors are mostly affecting the product quality with a least amount of
experimentation, thus it will save time and resources. The Taguchi method is best used for
intermediate number of variables (3 to 50), when few interactions are between the variables,
and when only a few number of variables contribute significantly.

3.2 DESIGN OF EXPERIMENT

Conventional experimental design methods were too complex and were not so easy to use.
Large number of experiments was carried out when the number of process parameters are

17
more. Thus to solve this problem, Taguchimethod uses a special design of orthogonal arrays
so as to study the entireparameter space by using only a small number of experiments.

These orthogonal arrays are basically special standard experimental design which requires
only a least number of experimental trials for finding the main factors influence on output.
Before opting for an orthogonal array, the lowest number of experiment to be conducted are
fixed which is based on the formula below

N Taguchi = 1+ NV (L – 1)

N Taguchi = Number of experiments to be conducted

NV = Number of parameters

L = Number of levels

In this work

NV = 3 and L = 3, Hence

N Taguchi = 1+ 4 (3-1) = 9

Therefore minimum of 9 experiments are to be conducted. According on this, orthogonal array

are to be selected that has at least 9 rows that is 9experimental runs will be carried.

The following standard orthogonal arrays are commonly used todesign experiments:

2-Level Arrays: L4, L8, L12, L16, L32

3-Level Arrays: L9, L18, L27

4-Level Arrays: L16, L32

For the present work L9 orthogonal design is sufficient. It will require a maximum of
27experiments for optimizing the parameters. Taguchi experimental design of experiments
suggested L9 orthogonal array, where only nine experiments are sufficient for optimizing the

18
parameters. Based on these influencing factors, the variables are also assigned at columns in
the orthogonal array. The last column is left as dummy, but none of the row should be left out.
Once the orthogonal array is opted, the experiments are selected according to the level
combinations. It is much important that all experiments are successfully conducted. The
performance parameters arenoted for each experimental run for analysis purpose.

Taguchi Orthogonal Array Design - L9 (3*3)

Table 3.1 depicts the taguchi orthogonal array selector that shows the set of orthogonal array
for the parameters and their respective levels. For three parameters and three levels L9
orthogonal array is selected from the array selector.

.Table 3.1 Array Selector

19
Table 5.2 Levels of process parameters used Taguchi L9 Orthogonal Array

3.3 S/N Ratio

For Taguchi's structure strategy, the plan parameters (the components that can be effectively
constrained by the originators) and clamor factors (the variables that can't be effectively
constrained by the planners, as natural elements) are considered as affecting for the item
quality. The Signal to Noise proportion is used in his examination that takes both the mean
and the inconstancy of the test esteems into record. The S/N proportion fundamentally relies
on the quality attributes of the procedure to be streamlined. For the most part, there are three
classifications of execution attributes for the examination of the S/N proportion; they are,
the lower-the-better, the ostensible the-better, and the higher-the-better .The S/N proportion
for every reaction is generally registered contrastingly as per the classification of the
presentation qualities and accordingly paying little mind to the class the bigger
S/Nproportion will compare to all the more likely procedure execution trademark. For
present examination the material evacuation rate factor is the-higher-the-better execution

20
 attributes. When the majority of the S/N proportions have been classified for each kept
running of an analysis, Taguchi portrays a graphical methodology for dissect the
information. For graphical methodology, the sign to clamor proportions and normal
reactions are plotted for every parameter against every one of its dimensions. The diagrams,
higher the better qualities were chosen lastly the affirmation tests were directed.

3.4 PROCEEDURES OF TAGUCHI METHOD

The breif structure of taguchi strategy is as per the following

• Identifying the goal

• Selecting the variables

• Identifying wild factors and running test conditions

• Selecting of levels for controllable and wild factors

• Calculating the absolute DOF (level of opportunity)

• Selecting appropriate symmetrical exhibit

• Assigning components to segment

• Executing tests according to the preliminary conditions in cluster

• Analyzing the got outcomes

• Confirming the outcomes

3.5APPLICATION OF S/N RATIO

The adjustment in the item's quality attributes which is under scrutiny; in light of a factor
presented in plan of investigation is essentially the sign of wanted impact. In spite of the fact
that, when analyses are directed, there might be various outer parameter which are not
planned into the analysis and may impact the result of the examinations. Generally the

21
commotion components are these outside variables and their impact on the aftereffects of the
quality trademark under test is known as clamor. The sign to commotion proportion is the
wellspring of estimating the affectability of the quality trademark which is researched in a
controlled domain, to those outer ruling variables (known as clamor factors) which are not
leveled out. The idea of S/N proportion was started in the electrical building field. Taguchi
successfully connected this hypothesis to accomplish the ideal dimension of parameters
from the tests.

The aim of carrying experiments is always to find the highest possible S/N ratio for the
result. A higher value of S/N ratio shows that the signal is much high than the random
influence of the noise factors. Product design or process operation consistent with highest
S/N ratio, always yields the optimum quality with minimum variance.
The S/N ratio is designed to measure the quality characteristics.
The Signal to Noise ratio basically expresses the scatter around a specific target value.
Scatter is smaller for larger ratios. Having knowing the S/N ratio value of the samples before
and after the experiment, Taguchi’s loss function is used for estimating the potential cost
saving from the improved product.
3.6ADAVANTAGE OF S/N RATIO OVER AVERAGE

For analyzing the influence of experiments involving multiple runs, the use of signal to
noise ratio over standard analysis is preferred. Analysis using the signal to noise ratio will
offer the following advantages:
1. It will provide guidance for selecting optimum level parameter based on least scatter
around the target and also on the average value close to the target.
2. It will offer objective comparison between two sets of experimental data having
variation around target and the deviation of the average data from the target value.

3.7ROLE OF ANOVA

Taguchi replaces full factorial experiment method with a lean, low cost, quicker, partial
factorial experiment. Taguchi’s design for the partial factorial is based on specially
developed OA’s. Since the partial experiment is just a sample of the full set of experiment,

22
 the analysis of the partial experiment must be included by an analysis of the confidence that
must be placed in the results. Analysis of Variance is routinely used that provides a measure
of confidence. This technique does not directly analyze the data, but instead determine the
variance of the data. The confidence is generally measured from the variance.
This analysis provides the variance for controllable and the noise factors. By
understanding the source and magnitude of variance, robust operating conditions can be
predicted. This is second benefit of this methodology.

3.8ANALYSIS OF VARIANCE (ANOVA)

Sir Ronald Fisher in the 1930’s developed this methodology to interpret the results from
agricultural experiments. It is not a complicated method but has a lot of mathematics associated
with it. ANOVA is a statistically based methodology and an objective decision-making tool for
determining and differentiating the average performance of groups of items tested.
3.7TABLES FOR TAGUCHI DESIGN OF EXPERIMENT
Tables for Taguchi design of experiment are shown below:
Table 3.3: Process Parameters and their levels
S.No. Parameters Units Level 1 Level 2 Level 3

1 Welding Voltage V 16 20 24

2 WeldingCurrent A 100 150 200

3 Welding Speed mm/sec 5 10 15

23
 Table 3.4: Experimentation L9 Orthogonal Array

S.No. Welding Voltage Welding Current Welding Speed

1 16 100 5

2 16 150 10

3 16 200 15

4 20 100 10

5 20 150 15

6 20 200 5

7 24 100 15

8 24 150 5

9 24 200 10

24
 4

EXPERIMENTATION

4.1EXPERIMENTATAL SETUP
ESAB MIGMATIC MIG welding machine is used for the present thesis to weld the samples.
The machine is as shown in the figure 4.1 on the next page while the specifications of the machine
are shown below. MIG welding uses a electrode in form of wire through the wire reel that is
constantly fed for producing arc and also serve the purpose of filler metal. Inert gas provides an
medium for sound weld. The machine was available at Punjab Body Builder, Sarojini Nagar
Industrial Area Lucknow.
Table 4.1 Technical Specifications of MIGMATIC 250

25
Figure 4.1: ESAB MIGMATIC 250 MIG welding machine

26
Figure 4.2: Welding ofspecimens on MIGMATIC 250 machine

27
 Figure 4.3 MIGMATIC 250 machine panel showing parameters
4.2WORK PIECE MATERIAL
The material used for the present work is Bright Mild Steelwith specification of 8 mm thickness
and 10 mm diameter.
Table 4.2 Properties of Mild Steel
Density Melting point Yield strength Elastic modulus Poisson’s Brinell
g/cm³ ºC MPa Gpa Ratio Hardness
7.85 1427 510 201 0.26 217
Table 4.3 Chemical composition of the workpiece material (Mild Steel) by weight
Material Fe Mn C Cu Si
% Composition 98.00 1.04 0.25 0.21 0.28

28
Figure 4.4: Mild Steel weldedwork pieces

29
Preparation of Work Samples

Figure 4.5 Mild Steel Flat Bars

30
Figure 4.6 Grinding of MS bar

31
Figure 4.7 Semi-finished MS Specimen

32
 Figure 4.8 Finishing of MS Specimen

4.3 Surface Roughness

The surface roughness of the welded bead surface had been measured using Roughness test
JIS1994 gauss standard. Lower surface roughness of the welded bead surface was the preferable
criteria that put into measured. Definitions and indications for surface roughness parameters (for
industrial products) are specified. They are arithmetical mean roughness (Ra), maximum height
(Ry), ten-point mean roughness (Rz), mean spacing of profile irregularities (Sm), mean spacing of
local peaks of the profile(S) and profile bearing length ratio(tp). Surface roughness is given as the
arithmetical mean value for a randomly sampled area. Mean center line roughness (Ra) is defined

33
in the annexes of JIS B 0031 and JIS B 0061. A portion stretching over a reference length in the
direction in which the average line extends is cut out from the roughness curve. In this lab testing,
samples of single and overlap weld beads were inspected using Mitutoyo SJ-400 surface
roughness machine. Data are measured at the top pitch of the weld bead. All data are measured 3
times for each sample at the 3 different pitches. The machine is set to follow JIS 1994 standard
(Misumi Corporation, 2014). Figure 3.7 shows the machine for the roughness test.

Figure 4.9: Mitutoyo SJ-400 machine

4.4Tensile Testing
Tensile testing is preformed on a UTM machine. The workpiece was cinched on the UTM
machine and tensile force is connected on it. On utilization of ductile force the workpiece
extended and after a time frame when the heap achieves a most extreme esteem, the workpiece
parts from the point where MIG welding was performed. This most extreme tensile force is noted
and in blend with the territory of utilization of ductile force, a tensile strength is determined for
every workpiece.

34
Figure 4.10 UTM Machine

35
Figure 4.11 Specimen before tensile loading on UTM

36
Figure 4.12 Specimen after breaking on UTM machine

37
 5

RESULT AND DISCUSSION

5.1 CALCULATION FOR TENSILE SRENGTH

The tensile strength of welded joint is estimated using universal testing machine (UTM). Tensile
load is applied on the specimen and the ultimate tensile load is recorded at which the welded joint
breaks. By using the value of ultimate tensile force and area subjected to tensile loading, the value
of tensile strength is estimated. The calculation of tensile strength is as follows:

Area subjected to tensile load for specimen = 3800 mm2

Maximum tensile load for Specimen 1 = 39.6 kN = 39.61 × 103 N

Maximum tensile load

Tensile Strength= tensile load ¿
Area subjected ¿

3
39.6 × 10 2
Tensile Strength of Specimen 1= =10.42 N /mm
3800

38
 Table 5.1: Calculation for Tensile Strength

Welding Voltage Welding Welding Tensile Strength

Exp. No Current Speed
N/mm2

16 100 5 10.43
1

16 150 10 11.10
2

16 200 15 11.50
3

20 100 10 11.89
4

20 150 15 12.45
5

20 200 5 13.14
6

24 100 15 13.98
7

24 150 5 15.10
8

24 200 10 15.98
9

The above table 5.1 depicts the calculation for tensile strength for the MIG welded specimens
as per L9 orthogonal array.

39
5.1.1 Calculation of S/N ratio for Tensile Strength

The S/N ratio, which condenses the multiple data points within a trial, depends on the type of
characteristics being evaluated. For calculation of S/N ratio for tensile strength LARGER IS
BETTER condition is opted. The equation for the calculation of S/N ratio for tensile strength is:

S/NLB = -10 log ( Σ (1/yi²) )

Table 5.2 Calculation of S/N ratio for Tensile Strength

Tensile Strength Signal to noise ratio (db)

S.No

10.43 20.3575
1
11.11 20.9066
2
11.51 21.2142
3
11.88 21.4891
4
12.46 21.9035
5
13.12 22.3653
6
13.98 22.9036
7
15.11 23.5796
8
15.98 24.0662
9

5.1.2 Calculation of Mean S/N ratio for Tensile Strength

Mean S/N ratio is calculated by using following formula

nfi= (nf1+nf2+nf3)/3

40
Wherenf is mean S/N ratio for factor f at the level value i of the selected factor.nf 1, nf2, nf3 are S/N
ratio for factor f at level u

The factors which affect the machining parameters show in the table as their respective ranks.
Rank of the parameters depends on the value of delta. If the delta value of one parameter is higher
than the other that shows first rank. Higher value of S/N ratio of each factor shows the optimal
level of the factor. Welding voltage shows the main effect in the below response table followed by
welding current. Weld speed is least effective as compared to other parameters.

Table 5.3 Calculation of mean S/N ratio for Tensile Strength

Level Welding Voltage Welding Current Welding Speed

1 20.84 21.59 22.10

2 21.93 22.14 22.16

3 23.53 22.56 22.02

Delta 2.68 0.97 0.16

Rank 1 2 3

Delta = (Highest mean S/N Ratio – Lowest mean S/N Ratio)

5.1.3 Analysis of Variance for Tensile Strength

The following table 5.4 shows ANOVA of Tensile Strength conducted on MINITAB 16.0. The
result shows that the contribution of welding voltage is most and is 87.86%. Welding current is
the second most influencing parameter for tensile strength with a contribution of 11.23% while

41
welding speed is the least dominating parameter and has negligible influence on tensile strength
having a contribution of only 0.65%.

Table 5.4 ANOVA of Tensile Strength

Source DOF SS Adj MS F Value Contribution

Welding Voltage 2 24.6349 12.3173 357.96 87.87%

Welding Current 2 3.1510 1.5751 45.76 11.24%

Welding Speed 2 0.1843 0.0922 2.67 0.64%

Error 2 0.0689 0.0345 0.25%

Total 8 28.0379 100%

At least 95% confidence

CALCULATIONS OF ANOVA

Table 5.5 Values of Tensile Strength corresponding to different levels of Welding Voltage

Welding Voltage Levels Value 1 Value 2 Value 3

16 10.43 11.11 11.51

20 11.88 12.46 13.14

24 13.98 15.11 15.98

42
 Means of each level of Welding Voltage are as follows:

10.42+11.10+11.50
Ā 1= =11.01
3

11.87+12.45+13.13
Ā 2= =12.48
3

13.97+15.10+ 15.97
Ā 3= =15.01
3

Mean of Means of each level of Welding Voltage is given as follows:

Ā = ( Ā 1+ Ā 2+ Ā 3 ¿/3= 12.84

Sum of Square for Welding Voltage is as follows:

∑ of Square=3 ¿]
SS of Welding Voltage= 3[(11.01−12.83 ¿ ²+ ( 12.48−12.83 )2+(15.01−12.83) ² ¿

SS of Welding Voltage= 25.76

Adj MS=
∑ of Square
Degree of Freedom

25.76
Adj MS of Welding Voltage= =12.88
2

Adj MS
F Value=
Adj MS Error

12.88
F Value of Welding Voltage= =374.468
0.0344

43
 Percentage Contribution=
∑ of Square
Total ∑ of Square

25.76
Percentage Contribution of WeldingVoltage= =91.86 %
28.04

Figure 5.1: Main effect plot forTensile Strength

Figure 5.1 presentsthe mean effect plot for Tensile Strength. It shows that the Tensile
Strengthincreases with both welding voltage and welding current. Welding voltage has major
influence on tensile strength followed by welding current. Moreover, with increase in the level
of welding voltage and welding current, the tensile strength is observed to follow an
increasing trend.

44
Welding speed is the least influencing factor for tensile strength and has negligible contribution
of only 0.65%.

Figure 5.2: Interaction plot for parameters and Tensile Strength

Figure 5.2depicts the interaction plot between tensile strength and welding current at different
levels of welding voltage. The plot depicts that the tensile strength increases with MIG
welding parameters at all levels. The tensile strength increases with welding current at every
level of welding voltage.

Optimal Levels of Parameters for Tensile Strength

 Welding Voltage : 24 V

 Welding Current :200 A

 Welding Speed :10 mm/sec

45
46
5.2 CALCULATION FOR SURFACE ROUGHNESS

For estimation of Surface Roughness, the workpiece is put beneath the surface harshness analyzer
and the stylus of the analyzer is moved over the machined surface. By the movement of stylus on
the machined surface, a normal estimation of surface harshness is shown by the analyzer on its
computerized meter. That esteem is written down for different workpiece. Three surface harshness
perusing were taken for every example and their normal was noted. These qualities are delineated
in the accompanying table 5.6.

Table 5.6: Calculation for Surface Roughness

Exp. No Welding Welding Current Welding Surface Roughness (Ra)

Voltage Speed

1 16 100 5 3.72

2 16 150 10 1.53

3 16 200 15 1.79

4 20 100 10 1.24

5 20 150 15 2.58

6 20 200 5 3.67

7 24 100 15 2.42

8 24 150 5 2.78

9 24 200 10 3.94

47
5.2.1 Calculation of S/N ratio for Surface Roughness

The S/N proportion, which gathers the numerous information focuses inside a preliminary, relies
upon the kind of qualities being assessed. For figuring of S/N proportion for surface roughness is
better condition is selected. This is considered as the imperfection and it ought to as low as could
be expected under the circumstances.

The equation for the calculation of S/N ratio for Surface Roughness is:

S/NSB = -10 log ( (1/n) Σ yi² )

Table 5.7Calculation of S/N ratio for Surface Roughness

S.No Surface Roughness Signal to noise ratio (db)

1 3.72 -11.3876

2 1.53 -3.6368

3 1.77 -5.0085

4 1.24 -1.7982

5 2.58 -8.2661

6 3.67 -11.3171

7 2.42 -7.6404

8 2.78 -8.9122

9 3.94 -11.8878

48
 5.2.2 Calculation of Mean S/N ratio for Surface Roughness

Mean S/N ratio is calculated by using following formula

nfi= (nf1+nf2+nf3)/3

Wherenf is mean S/N ratio for factor f at the level value i of the selected factor.

Table 5.8Calculation of mean S/N ratio for Surface Roughness

Level Voltage Current Speed

1 -6.677 -6.943 -10.538

2 -7.126 -6.937 -5.775

3 -9.481 -9.405 -6.973

Delta 2.804 2.469 4.766

Rank 2 3 1

5.2.3 Analysis of Variance for Surface Roughness

The following table 5.9 shows ANOVA of Surface Roughness. The result shows that the
contribution of welding speed is most and is 33.29%. Welding current is the second most
influencing parameter for tensile strength with a contribution of 14.77% while welding voltage is
the least dominating parameter and has a contribution of only 10.32%.

49
 Table 5.9 ANOVA of Surface Roughness

Source DOF SS Adj MS F Value Contribution

Welding Voltage 2 0.822 0.412 0.25 10.35%

Welding Current 2 1.175 0.588 0.35 14.97%

Welding Speed 2 2.648 1.324 0.80 33.39%

Error 2 3.3078 1.655 41.63%

Total 8 7.948 100%

At least 95% confidence

Optimal Levels of Parameters for Surface Roughness

 Welding Voltage: 16V

 Welding current :150A

 Welding speed : 10 mm/sec

50
 Figure 5.3:Main effect plot for Surface Roughness

The figure 5.3 shows that the surface begins to corrupt with increment in of welding voltage. As
we increment the dimension of welding voltage poor surface completion is acquired. For
welding current, the surface unpleasantness initially improves yet with further increment in the
benefit of welding current the surface gets corrupted. Welding pace is the most overwhelming
parameter for surface harshness of MIG welded joint for the present arrangement of parameters.
The chart demonstrates that the surface harshness initially diminishes with increment in the
benefit of welding speed. But on further increment in dimension of welding speed over 10
mm/sec, the surface unpleasantness marginally increments.

51
 Figure 5.4: Interaction plot for parameters and Surface Roughness

Figure 5.4 shows the cooperation plot between surface roughness and welding voltage at
various dimensions of welding speed. It delineates that at lower dimension of welding speed,
the surface harshness is higher. At the point when the welding voltage esteem is expanded at
lower dimension of speed, the surface unpleasantness get improved. At center dimension of
welding speed (10 mm/sec), the surface harshness got is lower. With increment in dimension
of voltage at medium speed, the surface corrupts. With regards to higher welding speed,
medium esteem surface harshness is accomplished.

52
5.4 CONFIRMATION TEST
Confirmation tests have been performed for Tensile Strength andSurface Roughnesswith their
optimum levels of process variables.
Table 5.10: Confirmation of expected and actual values of Tensile Strength
Experiment Optimum Machining Parameters Tensile Strength
No. Welding Welding Current Welding Speed Actual Expected
Voltage
1 24 200 10 15.98 16.22
Error (%) 1.50%

Table 5.11: Confirmation of expected and actual values of Surface Roughness

Experiment Optimum Machining Parameters Surface Roughness
No. Welding Welding Current Welding Speed Actual Expected
Voltage
1 16 150 10 1.53 1.64
Error (%) 7.89%

53
 6

CONCLUSIONS

The current test examination of MIG welding carried on mellow steel thinks about the impact of
MIG welding parameters for their improvement utilizing L9 symmetrical cluster of Taguchi
strategy. Elements like Welding Voltage, Welding Current and Welding Speed were picked and
their connections were found. These outcomes demonstrate the exhibition of parameters at various
dimensions to advance the Tensile Strength of welded joint and its surface unpleasantness. From
the investigation following ends were inferred:

 As we increase the level of welding voltage poor surface finish is obtained. For welding
current, the surface roughness first improves but with further increase in the value of
welding current the surface gets degraded.
 The surface roughness first reduces with increase in the value of welding speed.But on
further increase in level of welding speed above 10 mm/sec, the surface roughness
slightly increases.
 Welding voltage is the most ruling parameter for tensile strength and has a commitment
of 87.86%.

•Tensile Strength increments with both welding voltage and welding current. Welding voltage
has significant impact on rigidity pursued by welding current. Also, with increment in the
dimension of welding voltage and welding current, the rigidity is seen to pursue an expanding
pattern.

•Welding pace is the least affecting component for flexibility and has irrelevant duty of simply
0.65%.

•Welding speed is the major influencing parameter for surface cruelty with a responsibility of
33.29%.

54
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