Intentional Journal of Seiemfc and Research Publications, Volume 4, sue 5, May 2014 ISSN 22503153 402 Experimental Investigation of MIG Welding for ST-37 Using Design of Experiment S.Utkarsh', P. Neel’, Mayank T Mahajan’, P.Jignesh*, R. B.Prajapati® Abstract: In this roscarch work of Gas Metal Are Welding(GMAW) show the effect of Current(A), Voltage(V),Gas Flow rate(L/Min) and Speed(M/Min) on Ultimate Tensile Stength(UTS) of st-37 low alloy steel material, In this Experiment we done Experiment by using L9 orthogonal Array to find out UTS and also perform confirmatory Experiment to find out optimal run set of current, voltage speed and gas flow rate, Index Terms- MIG Welding,L9 Orthogonal Atray SIN ratio,ST- 31, 1. IyTRopucTION MIG welding is also recognized by gas metal are welding. It is a semi-automatic process by which the are length and feeding of wire into the are can be controlled automatically and operator skills required © positioning the gun at a correct angle and moving it along the scam at a controlled travel speed in the metal transfer depends upon modular and spray transfer, In the 1920's, the basic concept of GMAW was introduced but it was not commercially available until 1948. primarily it was considered to be, fundamentally, a high-current density, small diameter, bare metal electrode process using an inert gas for arc shielding, The application of this process was for welding aluminum and As a result, the term MIG (Metal Inert Gas) welding was used and till now 2 days. Subsequent process developments included operation at low-current densities and pulsed direct current, application to a broader range of materials, and the use of reactive gases(particularly CO2) and gas mixtures. The commercial metals like carbon steel low alloy and high alloy steels, stainless steels, aluminum , copper, titanium , zirconium «nickel alloys ean be welded by nuclear welding. By this process 1-13mm thickness range weld joints can be possible in any ‘welding positions. In this process consumable flux cored continuous wire for metallic electrode of diameter 0.8-2.4mm wound in spool form is fed at a required present speed through a welding gun, it picks up electric current from copper contact tube which is electrically connected to the DC power source and a shielding gases like argon, belium, carbon dioxide, carbon dioxide-argon mixture, argon-helium mixture, shielding gases are also use to cooled down the gun. MIG welding is use to increase productivity and consisteney of quality Fig. Sample of automatic GMAW welding Tl, LITERATURE REVIEW M.Agka Khani et al. studied for the material IS 2062 E5250 Mild stecl and take input parameter as wire feed rate(W),welding voltage(V)aozzle to plate distance(N),welding speed (s) and gas flow rate (g) and the response was the relationships between the ‘weld dilution and the five controllable input welding parameters such as wire feed wire, welding voltage, nozzle-to-plate distance, ‘welding speed, gas flow rate, And it was found that among main input welding parameters the effect of wire feed rate is significant. Increasing the wire feed rate and are voltage inereases the weld dilution where as increasing the nozzle to plate distance the welding speed results in decreases weld dilution and gas flow rate did not affect the weld dilution 1]. Gautam Kocher et al. studied for the material IS 2062 E250 Mild Steel and take input parameter as welding speed variable while are voltage(V),welding current(A),Wire feed. rate(W),Distance between the nozzle and the plates are fixed and the response was the effect of weld speed on penetration and reinforcement. This study was undertaken with the objective of determining the effects of weld speed on the weld profile and dilution analysis of the MIG butt welds of 182062 E250 A mild steel plates at constant wire speed rate and constant are voltage and welding current(2] ‘S.R.patil etal. studied for the material AISI 1030 Mild steel take input parameter as welding currentwvoltage,weld speed. The response was the signal-to-noise(S\N) ratio and www ijsrp orgSN 2250-5153, ANOVA (analysis of Variance) were used for optimization end It was found that tensile strength depends on welding speed. And the result show that by increasing the welding speed and decreasing the current increases the UTS of welded joint while voltage do not affect the weld strength(3] Harshal k chavan et al. studied single pass comer joint are evaluated by FMEA by ANSYS covers varying heat input, welding speed on thermo mechanical response of weld mint after cooling down to the room temperature. From Results shows that heat input, welding speed has significant impacts on the response[4} Ajit Hooda et al. studied for the material AIST 1040 Medium carbon Steel and take input parameter as welding voltage,current,wire speed and gas flow rate and the response was RSM(Response Surface Methodology) for maximum yield strength of joint. The similar weld joint of AISI 1040 material was developed effectively with MIG welding with selected range of input variable parameters, The longitudinal yield strength is greater than the transverse yield strength[ 5], Jpasupathy et al. studied forthe material A10S0 low carbon stee| and take input parameter as welding current, welding speed, Distance of electrode from work piece and the response was ‘ignal to Noise(S\N), ANOVA (analysis of Variance) for strength. The experiment value that is observed from optimal welding parameters, the strength & SIN ratof6] Miss Nibau Bhadauria et al studied for Experiments were conducted based on central composite face centered cubic design and mathematical models were developed for GMAW process parameters Tike vollage(V),welding speed(s) and gas flow rate(G).Using these models the direct effect of the process parameters on weld bead penetration were studied. And results shows that as penetration increases the strength of the weld[7] HSPark et al. studied for Experiment on optimizing the wire feed, speed against the welding speed for lap joint filet weld of 1.6 mm aluminum alloy which is used for light weight car body and the response was for the same welding speed has wire feed speed increases the bead becomes wider and the bead cross sectional area is ineveases. As wire feed speed increases the penetration changes from incomplete penetration to excessive melting. The objective function consist of the sum of the bead width, back bead width and bead cross section area for the objective function value 3 the weld quality is idcall8] A.RRahemanet et al, studied for Experiment on change in hardness, yield strength and UTS of welded joints produced in 137 grade steel his work focus on relationship between MIG welding variables and Mechanical Properties of st37 steel joint The welding current and welding speed were fixed on 135 A and 50 cm/min and effect of are voltage on mechanical properties of weld metal was investigated[9] Jnvenational Journal of Scicsifc and Research Publications, Volume 4, Issue S, May 2014 403 IIL EXPERIMENTAL PROCEDURE For the research purpose on MIG welding we have chosen the material ST37 after experiment work on different materials like MILD STEEL alloys, 182062 250, Low alloy steel ete. we get the our required material as st-37 which is low alloy steel. We fabricate 20 pieces into a dimensions of 100x75x6mm by laser cutting machine. Then we have made all the work pieces in to flate plate standard form with angle of 60°, ‘Then we had took two pieces and set it with maintaining a [.Smm root gap and then we had started penetration process with desired or selected curentvoltage,wire feed rate,gasflow rate readings and done the experiment with the skilled worker in Truetzschler India pvt.ltd with the permissions and guidelines of the manager. ‘Then we had done the all experiments and took readings and ‘made the calculation and table Table 1. Levels of process variables Tanai [a [teat [te a Carexta) [Aa [0 [120 [50 Tessa at 2s Water | wat | 4s | 338 | es ie ; ratgatimy_|_EM 5 ° ” ‘Table 2 Experimental layout using Ly orthogonal arty vay | aasttow | yo, canna) | GAS OX | vortaceie | srEEDaN uo ‘ 2 45 ie . 2 35 ie 2 3 oo ‘ 2 ss oo . 2 3 180 5 2 ss 0 A 2 as 130 i 1 33 In the welding experiments, we are used ER70S-6 with 0,9 mm_ diameter. The work pieces consisted of ST-37 Low alloy steel with thickness of 6mm.The chemical composition (wt.%) of both base metal and electrode wire are given Table 3 www ijsrp orgSN 2250-5153, Table 3. chemical composition (w.%) of work material and electrode wire used Jnvenational Journal of Scicsifc and Research Publications, Volume 4, Issue S, May 2014 404 Table 5. Response table for mean Material Swe Ps oun) Gas ST-37 | 113 | 0.028 | oar7 | 0007 | O07 ‘URRENT | VOLTAGE | SPEED Blectrode [| C Si_[ Mn) PS bevel a) vy | ewan) | TOWRATE Cirnos-s [0.10 _[1.00_[ 1.70 [ooo [ois (L/MIN) 1 | «73 | 302 | a2 | 1239 3,TAGUCHT'S DESIGN METHOD 7 aaa] 4365 | 442.7 | 3673 Taguchi technique is sed wo increases the output andredueed the | 3 | 356.9 | 433 | 3586 | 428.4 cos of te products, The Taguchi Designs based on orogens! [Deka] 78.6 | 862 | 842 | G2a the effect of Noise factor, Orthogonal array helps to reduced the Rank 3 1 2 4 time and cost of the experiment. The Signal-to-Noise (S/N) Ratio which are log function of required output which is the objective function to be optimized. larger is better SIN=-10*log(Q(/¥7)in) smaller is better IN=-10*l0g(X(Y*)in) Where y = responses for the given factor level combination 1 of responses in the factor level combination IV. RESULTS AND DISCUSSION In this research work the effect of input parameters on the Tensile strength were determine Table 4. Experimental result for uts and sin ratio Feptno] | oy | | @ | ursevnae) | sn Ratio 1 [uefa fas] « | soos | sons 2 [awl 2 [ss] 9 | ass | suas 3s [aw [= [es] | ans | saa = [mo [a [ss] | arae | some s [i | 2 [es] « | sm | saree © [am fs [as| 9 [sass [ szasea 7 [af [os] 9 | asa | saseas The result show that among the input parameters the voltage affects the most and it was observed that gas flow rate do not affect the weld strength. Greater SIN ratio results to better Quality show the optimimum level of process variables. Effect of current : In this experiment the major effect is produced by current & voltage it is most significant parameter among four available. current at value of 120A current we get the maximum s/n ratio of 52.8128 and ultimate tensile strength of 434.34(Nimm’). when the current is too low the molten metal fails 10 wet the joint surface and cause lack of fusion, with inereasing current the melting rate of the electrode is increases. Effect of voltage: In this experiment the major effect is produced by voltage it is most significant parameter among four available. voltage at value of 22V- we get the maximum sin ratio of $2,8128 and ultimate tensile strength of 434.34(Nimm). this is a very important variable in MIG welding, mainly because it determines the type of metal transfer by influencing the rate of drop late transfer across the are. the are voltage to be used depends on the base metal thickness, type of joint, electro composition and size, shielding gas composition, welding position, ype of weld and other factors Effect of speed: In this experiment the major effet is produced by speed itis significant parameter among four available, speed at value of 5.S(M/Min) speed we got maximum signal to noise ratio as 52.81, and at same Speed 5.5(M/Min) we get maximum ultimate tensile strength of 434.34(Nimm*), the linear rate (express in em/min or mmvsee) at which the are moves around along the joint termed are travel speed, affects weld bed size and penotration, with other variables kept constant, there isa certain Value of travel speed at which the weld penetration is maximum, Effect of gas flow rate: At the value of gas flow rate of 1O(LIMin) we get better signal to noise ratio as 52.62 and at 10(L/Min) Speed we get maximum ultimate tensile strength of 434,34(Nimm’). It is a least affective variable among four of the parameters. \V. CONCLUSIONS after the experiment we can say that the current and voltage as a input parameter create a significant effect finally we got the confirmatory experiment at below range and got the optimum value of strength and s/n ratio, www ijsrp orgserntional Jounal of Seine and Research Publications, Volume 4, lsu 5, May 2014 405 SN 2250-5153, Table 6 Confirmatory Test Range arent Voltage Speed Sis ow a w mn ratelLimis} 110 2 35 3 Table 7 Confirmatory Test Result TSN? SIN ratio 454.25 3.1459 VI. ACKNOWLEDGMENT TRUETZSCHLER INDIA PVI.LTD ALLOW US TO PERFORM TIE EXPERIMENT ON THE MIG WELDING FOR ST-37 THEY HAV PROVIDED US MATERIAL, TOOLS, HELPERS, BEST GUIDELINE AND INFORMATION ABOUT MIG WELDING 6, REFERENC [n) Gautam Kocher “EXPERIMENTAL ANALYSIS IN MIG WELDING WITH 1S ‘Advanced Engineering Technology, April-June, 2012, 158-162 [2] M. Aghaknan’, €. Mehrdag, and E. Hayat "Parametric Optimization o Gas Metal Arc Welding Process by Taguchi Method on Weld Dilution” International Journal of Modeing and Optimization , August 012,216 220 1B] SR. Pati, CA. Waghmare “OPTIMIZATION OF MIG_WELDING PARAMETERS FOR IMPROVING STRENGTH OF WELDED JOINTS , atl et al Intarnational Journal of Advanced Enginesrng Research and Studies, July Sept, 2013,24-16 ‘LPasupathy, V.Ravisarkar " PARAMETRIC OPTIMIZATION OF TIG WLLDING PARAMETERS USING TAGUCHI METHOD FOR DISSIMILAR JOINT " latrational Journal of Seieifc & Engineering Research, noverber-2013 [5] AftHoode, xenon Ohingra? and Satpal Sharma” OPTIMIZATION OF MIG WELDING PROCESS [6] PARAWETERS TO PREDICT MMAKIVUM YIELO STRENGTHK IN Al 3040"Intematonal Journal of Mechanleal Engineering and Raboting Reseateh INDIA, October 2012,203-213, [7] Me. Harsnal K. Chavan Mr. Gunwant D, Sheltie Dr. M. S. Kadam 'EHRECT OF HEAT INPUT’ AND SPEED OF WELDING ON DISTORTION 'N [MIG WELDING " international journal of industal engineering research and development uieRO} July-December (2012), 42-50 Is] Neha Bhadsura Pot. S. Oba” Optimization of Process Params for ‘Weld Bend Penetration of 152052 Mild Steel for GMAW Process Using Response Surface Methodology" International Joural of Advanced Research in Compuer Seleore and Software Enginering . Ociber 201230353, [9] A.RiBshman and H.Abshosscinh “CHANGE IN HARDNESS,YIELD STRENGTH AND UTS OF WELDED JOINTS PRODUCED OF ST37 GRADE STELL" Indi oural of Seience and Teehnology, Dee 2010. AUTHORS Correspondence Author - Utkarsh Shukla, ush.utkarsh@ gmail.com, 9638239838 www ijsrp org