Escolar Documentos
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-2016
Abstract- A vertical-position welding process is the one of challenging positions because the gravity force would be
affected to the metal transfer during the welding process which may be decreased in welding quality due to the welding fault.
Recently, the methods that used to detect the welding fault have still been based on off-line method which would be wasted
time and increased production cost because detecting of the welding fault could be done after the welding process finished.
In order to solve the problem, this study proposed a new algorithm based on Mahalanobis Distance (MD) method for on-line
monitoring system. Three different settings of arc voltage were chosen 23, 25 and 27 V to carry out the experiment to find
out the optimal arc voltage. From the experiment results, it confirmed that the developed optimal algorithm could be
achieved the highest quality of weld with the optimal arc voltage setting at 23 Vwhereas the welding quality was obtained
98.65% and 99.73%. Furthermore, the additional experiment has been verified that the developed algorithm using optimized
arc voltage obtained good welding quality.
Keywords- Vertical-position welding , Welding quality, On-line monitoring system, Mahalanobis distance, Welding fault.
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-9, Sep.-2016
different bead formation due to effect of gravitational achieved best quality of the weld. To quantify the
force although using same welding parameters [8]. welding quality, the transformed welding current and
And also, the welding quality that represented by arc voltage were analyzed using MD method. To
bead geometry is effected by the input energy verify the developed algorithms,the optimized arc
dissipation in the workpiece, as well as the voltage setting has finally been done through the
amountand the distributionsof input energy on surface additional experiment.
area of the workpiece [9].
II. EXPERIMENTAL PROCEDURES
The input energy is affected the amount of arc
voltage which influence the mechanical properties as This study employed bead-on-plate GMA welding
well as weld bead formation. As the increasing arc process which was carried on SS400 steel plates of
voltage produces the hardness value increased while size 40x40x10 mm3. The chemical compositions for
the ultimate tensile strength and yield strength base metal and filler wire are presented in Table
decreased [10]. On the bead formation during 1.Not only the constant current power source was
welding process, the arc voltage determines the used, but also the shielding gas has been chosenCO2.
fusion zone shape and weld reinforcement. The Sheets were cleaned with fresh steel wire brush
welding with high arc voltage produces flatter, wider followed by acetone swabbing just previous to
and shallower penetration than lower arc voltage [11]. welding process[15].
It is very important to monitor the on-line welding
quality automatically in order to improve the welding Table 1: Chemical composition for Base metal &
quality and reduce production cost [12]. Therefore, it filler wire
is significantly necessary the implementation of an
automatic on-line monitoring system to control the
welding process. To ensure the welding quality as
well as to avoid the weldingfault on the workpiece, a
real-time welding quality monitoring and controlling
systems have been applied in recent years [13]. The
Table 2 presents the experimental data for the
transformed welding current and arc voltage derived
welding parameters using the three different setting
from on-line monitoring system has been focused
of arc voltage.
onrecently.
Table 2: Experimental data
MD developed by Mahalanobis an Indian famous
statistician in 1936 is the robust and simple method
which might be employed to quantify the welding
quality. There are few studies related to the welding
quality by analyzing the welding current and arc
voltage distributionsfrom on-line welding process
based on MD [9,12-14].Kim et al.[9] performed the
welding quality of pipeline in overlay welding
process by analyzed the welding current and arc
voltage waveform to find the welding fault used MD
method. Feng et al. [12] used MD method to find
welding fault in GMAwelding process by performing The experiment was started with setting up the
the qualitative quantities analysis. equipment (as shown in Figure 1), and then the
square steel plate was positioned vertically. To
The reviewed literatures [9,12-14] mostly minimize the welding distortion during the welding
investigated on-line detection of welding fault and process, the plate was held in fix jig (see Figure
welding quality were limited on horizontal welding 2).The welding current and arc voltage were set
position. Therefore, this study takes into account to manually at the welding inverter and the digital data
develop the optimal algorithm of arc voltage on the acquisition system measured it during the GMA
vertical-position welding processes by analyzed the welding process. A specifically designed power
transformed welding current and arc voltage obtained supply was used to record the data. Initial trials are
from the on-line monitoring system using the MD performed to establishing adequate operating
method. The transformed arc voltage and welding condition. During GMA welding process, electrode
current data were derived from the experiment that move to downward direction with the welding speed
each data gained during the vertical-position welding has been programmed.
processwas 2500 data per second. The obtained
variations of arc voltage and welding current The arc voltage and the welding current waveforms
waveforms from the experiment were analyzed in that obtained during the experiment were calculated
order to find the optimal arc voltage setting by the quality of the weld using MD gained.
A Study of ARC Voltage Optimizing on Vertical-Welding Position Using Mahalanobis Distance Method by the Quality Prediction
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-9, Sep.-2016
The welding quality was calculated from the number seconds after the start, since welding quality at base
of the welding fault per second. The welding fault metal are generally unstable for the initial and the end
was determined using following steps; firstly the MD section area [13,14]. The reference was employed the
threshold value ( ) was set up. Secondly, using the experimental data from start position of each arc
threshold value 3 [9] , the welding fault was voltage setting, and the quality was quantified in
determined. Thirdly, the welding fault was calculated every 0.25 second.
in every 0.25 second. Ultimately, the welding fault
percentage is calculated to determine the welding
quality of the vertical-position welding process.
A Study of ARC Voltage Optimizing on Vertical-Welding Position Using Mahalanobis Distance Method by the Quality Prediction
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-9, Sep.-2016
wave length which accumulate around 0.75 to 1.75 length from 2 to 4 seconds. The high distance
seconds. Compared to waveform of arc voltage at the fluctuations occur slightly in the waveform. It can be
start position (Figure 5(a)), it has lesser fluctuations discovered in Figure 6(c) that the arc voltage
in wave length. As shown in Figure 5(d), the waveform at the middle position is more stable and
waveform of welding current at the middle position fewer fluctuations in wave length compared to the
slightly oscillates with little fluctuations in wave waveform of arc voltage at the start position in Figure
length. Compared to welding current at the start 6(a). Figure 6(d) indicates the welding current
position in Figure 5(b), the waveform of welding waveform at the middle position slightly oscillates
current at the middle position in Figure (5d) is more with small fluctuations in wave length. Compared to
stable which also has lesser fluctuations in wave the waveform of welding current at the start position
length. in Figure 6(b), welding current waveform at the
middle position has lesser fluctuations in wave length
and also more stable.
Figure 6.Arc voltage and welding current waveform of arc Figure 7. The comparison of welding quality among arc voltage
voltage setting at27 V at 23, 25, 27 V
The welding current waveform at the start position in Figure 7(b) shows the comparison of three different
Figure 6(b) shows has similar tendency with the setting of arc voltages at the middle position. It
waveform of arc voltage in Figure 6(a) that the wave discovered that the arc voltage setting at 23 V has the
length from 0 to 2 seconds is wider compare to wave average quality 99.73% and the lowest quality is
A Study of ARC Voltage Optimizing on Vertical-Welding Position Using Mahalanobis Distance Method by the Quality Prediction
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-9, Sep.-2016
98.4% at 0.25 and 2.56 seconds. Whilst the average The welding current and arc voltage have significant
welding quality of 25 V setting is 98.56% with the effect on welding quality whereas the waveform
lowest quality is 96.16% at 1.75 seconds. And then fluctuationsin wave length of both welding current
the arc voltage setting at 27 V has the average quality and arc voltage cause to decrease the quality of the
98.69% and its lowest quality is 88.16% at 1.25 weld. Much more high fluctuation in wave length will
seconds. From these data, the middle position of the lead to the weld quality more decreased. It means that
arc voltage setting at 23V achieved 99.73% which is when, the more wave length caused to the more
the highest welding quality. welding fault at the same time,the welding quality
decreased. Therefore it is very important to control
Figure 8 shows the comparison of the average the welding parameters especially welding current
qualities of three different arc voltage settingsat the and arc voltage to achieve the desired welding quality
start and middle positions. It can be observed that the from on-line monitoring system.
average qualities at the start and middle positions of
thearc voltage setting 23 V are 98.65% and 99.73%
respectively. Also it can be seen that the qualities of
the arc voltage setting 25 V which the quality of the
start position is 97.67% and the quality of the middle
position is 98.56%. The last setting is 27 V which the
quality at the start and middle are 98.68%, 98.69% in
series. From the observation, it is clearly shown that
23 V setting is the optimal setting compared those Figure 9. The positioned of data selection for analysis
two others, although the start position of 23 V setting
is slightly below the start position of 27 V setting, but
it has highest welding quality at the middle position.
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-9, Sep.-2016
has significantly important in welding fault detection Gas Industry, 30(4), 2010, pp.1-9.
[3] H. Anxin, X. Su, &S. Huafeng, Current situation of
process during the on-line monitoring system on
automatic welding of domestic long distance pipelines,
vertical-position GMA welding. Natural Gas Oil, 24(2), 2006, pp. 12-14.
[4] W. Rui, &R. Guo, Developments of Automatic Girth
CONCLUSIONS Welding Technology in pipelines,Electr. Weld Mach,
41(9), 2011, pp.53-59.
[5] Y. Zhifeng, Z. Wenwei, &Z. Zhihong. Development trend
The new algorithm using the MD technology to select of China's gas pipeline and relevant technical problem, Oil
the optimal arc voltage in GMA vertical-position Gas Storage Transp,31(5), 2012, pp. 321-325.
welding process and to quantify the welding quality [6] G. Yongdong, Z. Haiyan,& Z. Hongzhou, The Application
has been done in this study. Following conclusions of automatic welding technology in West-to-East gas
pipeline project, Oil Gas Storage Transp, 22(12), 2013,
have been drawn from the analysis: pp.53-55.
(1) The optimal arc voltage is 23 V which gained [7] L. Helin, L. Ji, &T. Wei, High grade line pipe and high
the highest quality of the weld whereby the pressure transportation: significant progress of oil & gas
transportation pipeline technology in China,China EngSci,
welding quality is 98.65% for start position and
12(5), 2010, pp.84-90.
99.73% for the middle position. The welding [8] D.W. Cho, S.J. Na, Cho, M.H. Cho,& J.S. Lee, A study on
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position at 25 and 27 V are 97.67, 98.56, 98.68 of Materials Processing Technology, 213(9), 2013,
pp.1640-1652.
and 98.69% respectively.
[9] I.S. Kim, J.H. Lee, J.P. Lee, M.H. Park, C.K. Park, Y.S.
(2) The optimal arc voltage predicted using the Kim, A Study on welding quality of pipe in overlay
developed algorithm could be achieved good welding process using Mahalanobis Distance method,
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98.01% at the start position and 99.36% at the [10] S.I. Talabi, O.B. Owolabi, J.A. Adebisi, T. Yahaya, Effect
of welding variables on mechanical properties of low
middle position. carbon steel welded joint, Advances in Production
(3) On GMA vertical-position welding process, the Engineering & Management, 9(4), 2014, pp.181-186.
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ACKNOWLEDGMENTS welding fault base on Mahalanobis Distance,International
Journal of Precision Engineering and Manufacturing,
This research was supported by Basic Science 12(6), 2011, pp.949-955.
Research Program through the National Research [13] R.R. Chand, A study on experimental and numerical
Foundation of Korea(NRF) funded by the Ministry of studies on mechanical characteristics for multi-pass GMA
Welding (master thesis), 2013, Mokpo National
Education (No. 2015R1D1A3A01020246) University, Mokpo, Korea.
[14] M. Toshio, T. Hidenori, O. Hiroyuki, K. Yu-ichi,
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A Study of ARC Voltage Optimizing on Vertical-Welding Position Using Mahalanobis Distance Method by the Quality Prediction
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