Analyzing the Effect of Process Parameters on the Weld Bead Geometry in Robotic GMAW using Taguchi Techniques

In the present scenario, as per statistics, more than 1.2 million welding robots are employed in the automation industry. This paper dealt with analyzing the effects of process parameters in the formation of weld bead geometry of robotic GMAW. The selected process parameters such as arc voltage, arc current, travel speed and stick out were optimized using Taguchi techniques. It focuses mainly on the effects of welding on bead penetration of weldment. From the experimental results, the maximum bead penetration occurs at I = 190 Amps, H = 3 mm and V = 20.2 volts. Similarly the minimum bead penetration 9.98 mm occurs at I = 220 Amps, H = 7 mm and V = 16.9 volts. Optimum process parameter levels obtained as a result of employing Taguchi techniques to achieve maximum bead penetration are 220 Amps of arc current, 3 mm stick out, 18 volts arc voltage and 0.175 mm/min electrode travelling speed. For the maximum bead penetration attainment, travel speed is a major influencing parameter followed by the parameter stick out as second major contributor.