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Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method

Year 2024, EARLY VIEW, 1 - 1

Hilal Kır Mustafa Yazar Şükrü Talaş

https://doi.org/10.2339/politeknik.1280163

Abstract

In this study, the effect of different weld projections on the mechanical properties of stud welds was analyzed using the Taguchi experiment planning method, using a projection welding machine with a capacity of 100 kVA with MFDC transformer. The samples were subjected to the tensile rupture force test with a destructive test device. The aim of this study was to ensure product safety by capturing the spot-welding quality, which is determined by the specifications of the automotive main industry, using a bolt with a lower weight. In this study, 1.5 mm WSS-M1A365-A11 uncoated steel sheet and 8.8 quality M6x1.00x25 triple projection uncoated welding bolts and 8.8 quality M6x1.00x18.5 ring shaped weld bolts were used as stud welding bolts. Different welding times, different welding currents and different welding clamping forces were used on the WSS-M1A365-A11 steel sheet samples in the stud welding operation with bolts. Taguchi analysis showed that ring shaped stud weld bolts required welding parameters of 32 ms welding time, 27 kA welding current and 500 daN welding force, while triple projection stud welding was found to perform the best optimum weld with 23 ms welding time, 18 kA welding current and 350 daN force.

Keywords

Projection welding Taguchi method Weld nozzle structure

Supporting Institution

Şahinkul Makina ve Yedek Parça Sanayi Tic. A.Ş.

Project Number

ARGE-2022-33 2201760000

Thanks

Scholarship in this study was supported by TÜBİTAK BİDEB (Turkish Scientific and Technological Research Council, Scientist Support Department) (Project No: 119C053).

References

  • [1] Paramonov, S.S., Bulychev, V.V., Maksimov, N.N., Ponomarev,A.I., “Improvement of zinc coated steel stamped part and steel nut projection welding process”, Materials Today: Proceedings, 38 (4), 1470-1473, (2021).
  • [2] Sejč, P. Belanová, J., Gábrišová, Z., Vanko, B., “The Influence of Parameters of the Resistance Projection Welding of M10 Steel Nuts to the Galvanized Steel Sheet DP 600 on Selected Joint Characteristics”, Manufacturing Technology, 20 (6), 822-833, (2020).
  • [3] Enrique P.D., Momani, H. A., Digiovanni, C., Jiao, Z., “Evaluation of Electrode Degradation and Projection Weld Strength in the Joining of Steel Nuts to Galvanized Advanced High Strength Steel”, Journal of Manufacturing Science and Engineering (J. Manuf. Sci. Eng.), 141 (10), (2019).
  • [4] Yetilmezsoy, K., Erhuy, C. G., Ateş, F., Bilgin, M.B., “Implementation of fuzzy logic approach to estimate the degree of expulsion and spattering index and weld strength in projection welding”, Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40:283, (2018).
  • [5] Mikno, Z., Stepień, M., & Grzesik, B., “Optimising the operation of servomechanical force systems used in the joining of thin-walled metal elements in the automotive industry”, 2015 International Conference on Sustainable Mobility Applications, Renewables and Technology (SMART), IEEE., Kuwait- Kuwait, pp. 1-8, (2015).
  • [6] Özgül, H. G., Arslan, S., “Investigation of the effects of different electrical resistance welding parameters on strength”, Sakarya University Journal of Science, 22(2), 673-679, (2018).
  • [7] Ha, S., Murugan, S. P., Marimuthu, K.P., Park, Y., Lee, H., “Estimation of lobe curve with material strength in resistance projection welding”, Journal of Materials Processing Technology, 263, 101-111, (2019).
  • [8] Anık, S. and Vural, M., “Alaşımsız Çeliklerin Kabartı (Projeksiyon) Kaynağı”, Makine ve Mühendis, 48(573), (2007).
  • [9] Bilga, P. S., Singh, S., Kumar, R., “Optimization of energy consumption response parameters for turning operation using Taguchi method”, Journal of Cleaner Production, 137, pages 1406-1417, (2016).
  • [10] Karaoğlan, A. D., and Kapçak, E., “Optimization of Welding Process Parameters Using Taguchi Method: an Application for Nut Welding Operation”, VIII. INSAC International Congress on Natural and Engineering Sciences (ICNES-2022), Konya-Türkiye, 51-60, (2022).
  • [11] Meral, G., Sarıkaya, M., Dilipak, H., “The optimization of cutting of parameters in drilling processes by Taguchi method”, Erciyes University Journal of the Institute and Technology, 27(4): 332-338, (2011).
  • [12] Ada, H., Çetinkaya, C., Durgutlu, A., “Radiographic and macrographic investigations of welding parameters determined by Taguchi method in API 5L X65 pipe joints”, Journal of Polytechnic, 22 (2), 375-384, (2019).
  • [13] Bıyık, A. İnce, U., Ateş, F., Yetilmezsoy, K., “Determination of Optimized Process Parameters by Using Taguchi and Multi-Objective Optimization Methods, Intended for Minimization of Burring Defect While Joining the Welding Bolts With Projection Welding Operation”, Mühendis ve Makina, 57, 677, (2016).
  • [14] Ramasamy, S., Gould, J., Workman, D., “Design of experiments study to examine the effect of polarity on stud welding”, Welding Journal, 81(2), 19/s-26/s, (2002).
  • [15] Shan, H., Yang, B., Ma, Y., Lou, M., Feng, Q., Li, Y., Lin, Z., “Friction stud riveting (FSR) of thick high-strength aluminum alloy structure”, International Journal of Machine Tools and Manufacture, 177, 103889, (2022).
  • [16] Nishikawa, N., “The principle and application field of stud welding”, Welding International, 17(9), 699-705, (2003).
  • [17] Talaş, Ş, Doğan, M., Çakmakkaya, M. and Kurt, A., “The Effect of Voltage on the Arc Stud Welding of Microwave Sintered Fe plus Al Powder Mixture”, Materials Research, 17(3), (2014).
  • [18] Thakur, A.G., Rao, T. E., Mukhedkar, M. S., “Nandedkar, V. M., Application of Taguchi Method for Resistance Spot Welding of Galvanized Steel”, ARPN Journal of Engineering and Applied Sciences, 5(11), 22-26, (2010).
  • [19] Tutar, M., Aydın, H., Bayram, A., “The optimisation of welding parameters for electrical resistance spotwelded TWIP steels using a Taguchi method”, Pamukkale University Journal of Engineering Sciences, 24(4), 650-657, (2018).
  • [20] Han, G. Ha, S., Marimuthu, K.P., Murugan, S. P., Park, Y., Lee, H., “Shape optimization of square weld nut in projection welding”, The International Journal of Advanced Manufacturing Technology, 113, 1915–1928, (2021).
  • [21] Tolf, E., Hedegard, J., “Resistance Nut Welding: Improving The Weldability and Joint Properties of Ultra High Strength Steels”, Welding in the World, 51 (3-4), 28-36, (2007).
  • [22] Dejans, A., Moens, D., Rymenant, P. V., “Copper-aluminium joining by novel locked projection welding process”, Welding in the World, 1-11, (2023).
  • [23]. Mikno, Z., “Projection welding of nuts involving the use of electromechanical and pneumatic electrode force”, The International Journal of Advanced Manufacturing Technology, 99,1405–1425, (2018).
  • [24] Mikno, Z., “Projection welding with pneumatic and Servomechanical electrode operating force systems”, Welding Research (Weld J), vol. 95, pp. 286-299, (2016).
  • [25] Sun, B., “Effect of projection height on projection collapse and nugget formation—a finite element study”, Supplement to the Welding Journal, September, 211s-216s, (2001).
  • [26] “Welding Processes: Welding, Part 2: Chapter 2- Projection Welding”, Welding Handbook, Ninth Edition, Vol. 3, Editor: A. O’Brien, American Welding Society, Miami, (2007).
  • [27] Tang, H., Hou, W., Hu, S., “Forging force in resistance spot welding”, Proc Inst Mech Eng, Part B: Journal of Engineering Manufacture, 216(7), 957,968, (2002).

Kabartı Türlerinin Saplama Kaynak Dayanımına Etkisinin Taguchi Yöntemiyle İncelenmesi

Year 2024, EARLY VIEW, 1 - 1

Hilal Kır Mustafa Yazar Şükrü Talaş

https://doi.org/10.2339/politeknik.1280163

Abstract

Bu çalışmada, MFDC trafolu 100 kVA kapasiteli projeksiyon kaynak makinası kullanılarak farklı kaynak kabartı yapılarının saplama kaynaklarının mekanik özelliklerine olan etkisi, Taguchi deney planlama yöntemi kullanılarak analiz edilmiştir. Numuneler tahribatlı test cihazı ile çekme koparılma kuvveti testine tabi tutulmuştur. Bu çalışmanın amacı, başta otomotiv ana sanayinin şartnamelerle belirlemiş olduğu punta kaynak kalitesini, ağırlığı daha düşük olan bir cıvata ile yakalayarak ürün güvenliğini sağlamaktır. Çalışmamızda 1,5 mm WSS-M1A365-A11 kaplamasız çelik sac ve saplama kaynak cıvatası olarak ise 8,8 kalite M6x1.00x25 üç kabartılı kaplamasız kaynak cıvatası ve 8.8 kalite M6x1,00x18,5 çember kabartılı kaynak cıvatası kullanılmıştır. WSS-M1A365-A11 çelik sac numuneleri üzerine, kaynak cıvataları ile nokta kaynak operasyonunda değişken olarak farklı kaynak süreleri, farklı kaynak akımları ve farklı kaynak baskı kuvvetleri kullanılmıştır. Taguchi analizleri göstermiştir ki, Ring kabartılı saplama kaynak parametreleri, 32 ms kaynak zamanı, 27 kA kaynak akımı ve 500 daN kaynak kuvveti gerektirirken, üç kabartılı saplama kaynak optimum kaynak civatası için 23 ms kaynak zamanı, 18 kA kaynak akımı ve 350 daN kuvveti olarak bulunmuştur.

Keywords

Projeksiyon kaynak Taguchi yöntemi Kaynak çentik yapısı

Project Number

ARGE-2022-33 2201760000

References

  • [1] Paramonov, S.S., Bulychev, V.V., Maksimov, N.N., Ponomarev,A.I., “Improvement of zinc coated steel stamped part and steel nut projection welding process”, Materials Today: Proceedings, 38 (4), 1470-1473, (2021).
  • [2] Sejč, P. Belanová, J., Gábrišová, Z., Vanko, B., “The Influence of Parameters of the Resistance Projection Welding of M10 Steel Nuts to the Galvanized Steel Sheet DP 600 on Selected Joint Characteristics”, Manufacturing Technology, 20 (6), 822-833, (2020).
  • [3] Enrique P.D., Momani, H. A., Digiovanni, C., Jiao, Z., “Evaluation of Electrode Degradation and Projection Weld Strength in the Joining of Steel Nuts to Galvanized Advanced High Strength Steel”, Journal of Manufacturing Science and Engineering (J. Manuf. Sci. Eng.), 141 (10), (2019).
  • [4] Yetilmezsoy, K., Erhuy, C. G., Ateş, F., Bilgin, M.B., “Implementation of fuzzy logic approach to estimate the degree of expulsion and spattering index and weld strength in projection welding”, Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40:283, (2018).
  • [5] Mikno, Z., Stepień, M., & Grzesik, B., “Optimising the operation of servomechanical force systems used in the joining of thin-walled metal elements in the automotive industry”, 2015 International Conference on Sustainable Mobility Applications, Renewables and Technology (SMART), IEEE., Kuwait- Kuwait, pp. 1-8, (2015).
  • [6] Özgül, H. G., Arslan, S., “Investigation of the effects of different electrical resistance welding parameters on strength”, Sakarya University Journal of Science, 22(2), 673-679, (2018).
  • [7] Ha, S., Murugan, S. P., Marimuthu, K.P., Park, Y., Lee, H., “Estimation of lobe curve with material strength in resistance projection welding”, Journal of Materials Processing Technology, 263, 101-111, (2019).
  • [8] Anık, S. and Vural, M., “Alaşımsız Çeliklerin Kabartı (Projeksiyon) Kaynağı”, Makine ve Mühendis, 48(573), (2007).
  • [9] Bilga, P. S., Singh, S., Kumar, R., “Optimization of energy consumption response parameters for turning operation using Taguchi method”, Journal of Cleaner Production, 137, pages 1406-1417, (2016).
  • [10] Karaoğlan, A. D., and Kapçak, E., “Optimization of Welding Process Parameters Using Taguchi Method: an Application for Nut Welding Operation”, VIII. INSAC International Congress on Natural and Engineering Sciences (ICNES-2022), Konya-Türkiye, 51-60, (2022).
  • [11] Meral, G., Sarıkaya, M., Dilipak, H., “The optimization of cutting of parameters in drilling processes by Taguchi method”, Erciyes University Journal of the Institute and Technology, 27(4): 332-338, (2011).
  • [12] Ada, H., Çetinkaya, C., Durgutlu, A., “Radiographic and macrographic investigations of welding parameters determined by Taguchi method in API 5L X65 pipe joints”, Journal of Polytechnic, 22 (2), 375-384, (2019).
  • [13] Bıyık, A. İnce, U., Ateş, F., Yetilmezsoy, K., “Determination of Optimized Process Parameters by Using Taguchi and Multi-Objective Optimization Methods, Intended for Minimization of Burring Defect While Joining the Welding Bolts With Projection Welding Operation”, Mühendis ve Makina, 57, 677, (2016).
  • [14] Ramasamy, S., Gould, J., Workman, D., “Design of experiments study to examine the effect of polarity on stud welding”, Welding Journal, 81(2), 19/s-26/s, (2002).
  • [15] Shan, H., Yang, B., Ma, Y., Lou, M., Feng, Q., Li, Y., Lin, Z., “Friction stud riveting (FSR) of thick high-strength aluminum alloy structure”, International Journal of Machine Tools and Manufacture, 177, 103889, (2022).
  • [16] Nishikawa, N., “The principle and application field of stud welding”, Welding International, 17(9), 699-705, (2003).
  • [17] Talaş, Ş, Doğan, M., Çakmakkaya, M. and Kurt, A., “The Effect of Voltage on the Arc Stud Welding of Microwave Sintered Fe plus Al Powder Mixture”, Materials Research, 17(3), (2014).
  • [18] Thakur, A.G., Rao, T. E., Mukhedkar, M. S., “Nandedkar, V. M., Application of Taguchi Method for Resistance Spot Welding of Galvanized Steel”, ARPN Journal of Engineering and Applied Sciences, 5(11), 22-26, (2010).
  • [19] Tutar, M., Aydın, H., Bayram, A., “The optimisation of welding parameters for electrical resistance spotwelded TWIP steels using a Taguchi method”, Pamukkale University Journal of Engineering Sciences, 24(4), 650-657, (2018).
  • [20] Han, G. Ha, S., Marimuthu, K.P., Murugan, S. P., Park, Y., Lee, H., “Shape optimization of square weld nut in projection welding”, The International Journal of Advanced Manufacturing Technology, 113, 1915–1928, (2021).
  • [21] Tolf, E., Hedegard, J., “Resistance Nut Welding: Improving The Weldability and Joint Properties of Ultra High Strength Steels”, Welding in the World, 51 (3-4), 28-36, (2007).
  • [22] Dejans, A., Moens, D., Rymenant, P. V., “Copper-aluminium joining by novel locked projection welding process”, Welding in the World, 1-11, (2023).
  • [23]. Mikno, Z., “Projection welding of nuts involving the use of electromechanical and pneumatic electrode force”, The International Journal of Advanced Manufacturing Technology, 99,1405–1425, (2018).
  • [24] Mikno, Z., “Projection welding with pneumatic and Servomechanical electrode operating force systems”, Welding Research (Weld J), vol. 95, pp. 286-299, (2016).
  • [25] Sun, B., “Effect of projection height on projection collapse and nugget formation—a finite element study”, Supplement to the Welding Journal, September, 211s-216s, (2001).
  • [26] “Welding Processes: Welding, Part 2: Chapter 2- Projection Welding”, Welding Handbook, Ninth Edition, Vol. 3, Editor: A. O’Brien, American Welding Society, Miami, (2007).
  • [27] Tang, H., Hou, W., Hu, S., “Forging force in resistance spot welding”, Proc Inst Mech Eng, Part B: Journal of Engineering Manufacture, 216(7), 957,968, (2002).
There are 27 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Research Article
Authors

Hilal Kır 0000-0002-9623-4738

Mustafa Yazar 0000-0001-9927-3268

Şükrü Talaş 0000-0002-4721-0844

Project Number ARGE-2022-33 2201760000
Early Pub Date July 17, 2023
Publication Date
Submission Date April 10, 2023
Published in Issue Year 2024 EARLY VIEW

Cite

APA Kır, H., Yazar, M., & Talaş, Ş. (2023). Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method. Politeknik Dergisi1-1. https://doi.org/10.2339/politeknik.1280163
AMA Kır H, Yazar M, Talaş Ş. Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method. Politeknik Dergisi. Published online July 1, 2023:1-1. doi:10.2339/politeknik.1280163
Chicago Kır, Hilal, Mustafa Yazar, and Şükrü Talaş. “Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method”. Politeknik Dergisi, July (July 2023), 1-1. https://doi.org/10.2339/politeknik.1280163.
EndNote Kır H, Yazar M, Talaş Ş (July 1, 2023) Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method. Politeknik Dergisi 1–1.
IEEE H. Kır, M. Yazar, and Ş. Talaş, “Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method”, Politeknik Dergisi, pp. 1–1, July 2023, doi: 10.2339/politeknik.1280163.
ISNAD Kır, Hilal et al. “Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method”. Politeknik Dergisi. July 2023. 1-1. https://doi.org/10.2339/politeknik.1280163.
JAMA Kır H, Yazar M, Talaş Ş. Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method. Politeknik Dergisi. 2023;:1–1.
MLA Kır, Hilal et al. “Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method”. Politeknik Dergisi, 2023, pp. 1-1, doi:10.2339/politeknik.1280163.
Vancouver Kır H, Yazar M, Talaş Ş. Investigation on the Effect of Projection Types on Stud Weld Strength by Taguchi Method. Politeknik Dergisi. 2023:1-.

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