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Multi-objective optimal design of small scale resistance spot welding process with principal component analysis and response surface methodology

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Abstract

This paper investigates the effects of welding parameters on the welding quality and optimizes them in the small scale resistance spot welding (SSRSW) process. Experiments are carried out on the basis of response surface methodology technique with different levels of welding parameters of spot welded titanium alloy sheets. Multiple quality characteristics, namely signal-to-noise (S/N) ratios of weld nugget diameter, penetration rate, tensile shear load and the failure energy, are converted into an independent quality index using principal component analysis. The mathematical model correlating process parameters and their interactions with the welding quality is established and discussed. And then this model is used to select the optimum process parameters to obtain the desired welding quality. The verification test results demonstrate that the method presented in this paper to optimize the welding parameters and enhance the welding performance is effective and feasible in the SSRSW process.

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Acknowledgments

The authors are grateful for the financial supported by the National Natural Science Foundation of China (11072083) and the Chinese Universities Scientific Fund (C2009M002). The authors are also grateful for the experiment supported by the analysis and test centre of Huazhong University of Science and Technology and Dongfeng Peugeot Citroen Automobile Company Limited.

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Authors and Affiliations

  1. Department of Mechanics, School of Civil Engineering and Mechanics, Huazhong University of Science and Technology, Wuhan, 430074, China

    Dawei Zhao & Yuanxun Wang

  2. Grand Master Trading Limited, Miyachi Unitek Corporation, Nanjing, 211100, China

    Suning Sheng & Zongguo Lin

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  1. Dawei Zhao
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  2. Yuanxun Wang
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  3. Suning Sheng
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  4. Zongguo Lin
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Correspondence to Dawei Zhao.

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Zhao, D., Wang, Y., Sheng, S. et al. Multi-objective optimal design of small scale resistance spot welding process with principal component analysis and response surface methodology. J Intell Manuf 25, 1335–1348 (2014). https://doi.org/10.1007/s10845-013-0733-2

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