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Analysis of weld bead characteristics on GMAW by changing wire electrode geometry

Sripriyan K., Ramu M.

Journal of Achievements in Materials and Manufacturing Engineering

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2016

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Vol. 78, nr 2

49--58

EN

Purpose: Welding is one of the important processes for the manufacture of a wide variety of products. Most of the manufactured products have to be produced by welding due to its greater productivity and economical viability. Still quality has to be enhanced in the products. To attain the perfect quality in weld a new attempt has been tried out while existing process are being optimized. In this direction, the conventional Gas Metal Arc Welding (GMAW) has been developed to encourage high welding performance variant. Influence of changing filler metal geometry is one of the ways to improve the capability of giving high deposition rate and penetration. Accordingly, a flat wire arc welding system has been developed and weld bead characteristic has been investigated. The overall results show that, the proposed technique of changing wire electrode geometry can be used effectively to improve the weld bead characteristics. In this article, how does a change in electrode geometry contribute to the weld quality in manufacturing industries, is well- verified by experimental results, which are also explored here.

2

Gatunki drutów, charakterystyka i korzyści płynące z ich zastosowania

Poroś D., Zaborski S.

Świat Obrabiarek

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2012

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R. 7, nr 10-12

23-27

PL

Przedstawiono elektrody drutowe jednolite z różnych materiałów jak i pokrywane cynkiem, tlenkiem cynku, mosiądzem i srebrem. Druty te mają zastosowanie do wycinania elektroerozyjnego elementów z materiałów trudno obrabialnych. Podano również ogólne wskazania co do warunków i parametrów obróbki, w których można te elektrody stosować. Skomentowano możliwości uzyskiwania określonych efektów wycinania elektroerozyjnego.

3

Zastosowanie metod statystycznych do monitorowania procesu obróbki elektroerozyjnej elektrodą drutową

Nowakowski A., Majerski P.

Inżynieria Maszyn

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2011

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R. 16, z. 3

24-31

PL

Dla potrzeb monitorowania procesów wycinania i mikrowycinania elektroerozyjnego opracowano modele statystyczne wykorzystujące mechanizm średniej kroczącej. W przypadku wycinania średnia krocząca opisuje proces zmian wartości czasu opóźnienia wyładowań. Przy mikrowycinaniu średnia krocząca śledzi proces ewolucji wybranych trzech typów impulsów napięcia międzyelektrodowego. Przedstawione metody mogą być wykorzystane zarówno do kontroli przebiegu procesów WEDM jak i mikro-WEDM. Modele zweryfikowano w trybie off-line, wykorzystując zrejestrowane ciągi impulsów napięcia międzyelektrodowego oraz podczas obróbki, implementując go w mikroprocesorowych analizatorach procesu.

EN

The paper presents investigations of the WEDM and micro-WEDM processes degeneration, carried out with MEDIOS-20 and the experimental micro-WEDM machine MW50 type developed in IZTW. The measuring stand consisted of the WEDM machines connected with the gap voltage pulses analysers, the data logger, the PC computer with the dedicated software for data acquisition and processing. The main tool used for prediction of the both processes degeneration was the moving average (MA) model, endowed with a parameter q, which plays a role of a smoothing parameter as well as a 'memory' window. During the WEDM machining the subject of the analysis was the delay time of discharges. In the micro-WEDM process the data input for the model was the transient numerical time series received from the gap voltage discriminating system, which separated the gap voltage pulses into three classes: idle, normal and short, according to their amplitude before discharge and the voltage drop during discharge. During the analysis it has been observed, that very often the MA for the degenerated processes decreased just before the wire braking, whereas this almost never happened for the stable one. Algorithms calculated the on-line process degradation level (WZ) were derived from the above model. The off-line verification of the presented models, performed with the registered data, showed their good reliability. The algorithm was both applied in a microprocessor controller and verified on-line during the machining.