Optimization of quality characteristics parameters in a pulsed metal inert gas welding process using grey-based Taguchi method

Optimization of a manufacturing process has to take into accounts all of the factors that influence the product quality and productivity. Optimization of welding process parameters is considerably complex because welding is a multi-variable process, which is influenced by a lot of process uncertainties. In this paper, a grey-based Taguchi method has been adopted to optimize the pulsed metal inert gas welding process parameters. Many quality characteristic parameters are combined into one integrated quality parameter by using grey relational grade or rank. The welding process parameters considered in this analysis are pulse voltage, background voltage, pulse frequency, pulse duty factor, wire feed rate, and table feed rate. The quality parameters considered are the tensile strength, bead geometry, transverse shrinkage, angular distortion, and deposition efficiency. Analysis of variance has been performed to find out the impact of individual process parameter on the quality parameters. If the tensile strength as the most important quality parameter is assigned a higher weight, then the pulse voltage was found to be the most influential process parameter. Experiments with the optimized parameter settings, which have been obtained from the analysis, are given to validate the results.