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Procedia Engineering 10 (2011) 2797–2802

ICM11

Prediction of Submerged Arc Welding Yield Parameters

through Graphical Technique
Aniruddha Ghosha,Somnath Chattopadhyayab,R.K.Dasb,P.K.sarkarb ,a*
a
Govt College of Engg& Textile Technology,Berhampore,West Bengal,India
b
Dept of ME&MME,Indian School of Mines,Dhanbad,India

Abstract

In submerged arc welding (SAW), selecting appropriate values for process variables is essential in order to control
bead size and quality. Also, condition must be selected that will ensure a predictable weld bead, which is critical for
obtaining high quality. In this investigation, mathematical models (based on multi-regression method) have been
developed and side by side prediction through artificial neural networks has been made. A comparative study has also
been done. Based on multi-regressions and a neural network, the mathematical models have been derived from
extensive experiments with different welding parameters and complex geometrical features. Graphic displays also
represent the resulting solution on bead geometry that can be employed to probe the model further. The developed
systems enable to put in the desired weld dimensions and select the optimal welding parameters. The experimental
results have proved the capability of the developed system to select the welding parameters in SAW process
according to complex external and internal geometry features of the substrate.

© 2011 Published by Elsevier Ltd. Open access under CC BY-NC-ND license.

Selection and peer-review under responsibility of ICM11

Key words:SAW,Neural Network,Regression model,Graphical Technique

1. Introduction

In the early days, arc welding was carried out manually so that the weld quality could be totally controlled
by the welder ability. The welder, when welding, can directly monitor flow pattern in puddle and make
immediate adjustments in welding parameters to obtain a good weldability.To consistently produce high-
quality weldability, arc welding requires welding personnel with significant experience. One reason for
this is the need for properly selecting welding parameters for a given task in order to ensure good weld

* Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 .

E-mail address: author@institute.xxx .

1877-7058 © 2011 Published by Elsevier Ltd. Open access under CC BY-NC-ND license.
Selection and peer-review under responsibility of ICM11 doi:10.1016/j.proeng.2011.04.465
2798 Aniruddha Ghosh et al. / Procedia Engineering 10 (2011) 2797–2802

quality which may be identified by its microstructure and the amount of spatter, and relies on the correct
bead geometry size. Therefore, the use of the control system in arc welding can eliminate much of the
guess-work often employed by welders to specify welding parameters for a given task [1].In addition to
that of specific importance is the development of mathematical models that can be employed to predict
welding parameters about arc welding parameters in arc welding process with respect to the work piece
and bead geometry to develop a robotic welding system. The submerged arc welding is one of the major
fabrication processes in industry because of its inherent advantages, including deep penetration and a
smooth bead [2, 3].Critical sets of input variables are involved in this process, which are needed to
control it. For this reason, in the application of SAW, engineers often face the problem of selecting
appropriate and optimum combinations of input process-control variables for achieving the required weld
bead quality or predicting the weld bead quality for proposed process-control-variable values[4].For
automatic SAW, the control parameters must be fed to the system. According to some mathematical
formulae it may come from multi-regression method or artificial neural networks or any other suitable
and efficient method to achieve the desired results [5].These important problems can be solved with the
development of mathematical models through effective and strategic planning, design and execution of
experiments. Already many efforts have been carried out in the development of various algorithms in the
modelling of arc welding process using various technologies [6,7,8,9].Multiple regression techniques are
used to establish the empirical models for various arc welding processes[6,7].However ,the regression
techniques cannot describe adequately most of the arc welding process as a whole. One of the artificial
intelligence (AI) techniques, a neural network as a tool for incorporating knowledge in a manufacturing
system is a massively interconnected network of simple elements and their hierarchical organizations.
These processes are characterized by welding parameters due to lack of adequate mathematical models to
relate these parameters to bead geometry [8, 9].More over numerical techniques such as finite element
method (FEM) also have several limitations. The potentially viable processing routes are numerous and,
therefore, various intelligent systems are necessary to identify optimal processing parameters [10].Now, it
is possible to make this selection with the help of a computer, and complex simulations become an
effective memory device for choosing the welding parameters. Also, arc welding requires a steady hand
to keep the electrode at a constant distance from the part being welded. At the same time , the hand has to
move at constant speed, it has to adjust for distance, as the electrode shortens. This operation requires
hundreds of hours of practice, burning expensive electrodes. There are many systems that simulate a
welding machine and permit significant saving in consumables. The selection of welding parameters for a
given welding process is based on experimental methods and human qualifications, according to
fabrication standards and empirical rules [11].This paper represents the development of intelligent system
to obtain detailed information about bead geometry in relation to the welding conditions, and to provide
the welding engineer with sufficient information to design the most economical and reliable welded
components for a given set of fabrication conditions.
The experiments were conducted by taking job 300x300x15 mm (3 pieces) was firmly fixed to a base
plate by means of tack welding and then the welding was carried out. The welding parameters were noted
during actual welding to determine the fluctuations, if any. The slag was removed and the job is allowed
to cool down. The job was cut at three sections with a hacksaw cutter and the average values of the
penetration, reinforcement height and width were taken down using vernire calliper of least count
0.02mm.

Nomenclature
Q Heat input
F Wire feed rate
 Aniruddha Ghosh et al. / Procedia Engineering 10 (2011) 2797–2802 2799

2. Experimental Results

Table-1: Observed Values for Bead Parameters

Heat input Wire feed rate Penetration Reinforcement Width
(kj/cm) (cm/min) (mm) height(mm) (mm)

6.15 60 3.4 1.5 13.5

12.31 60 3.5 1.7 10.2

6.15 120 4 1.9 15.6

12.31 120 4.7 2.3 11

3.20 60 3.2 1.2 10.2

6.40 60 3.24 1.4 8.3

3.20 120 3.3 1.8 9.9

6.40 120 3.52 1.5 9.2

2. Model Development, Files should be in MS Word format only and should be formatted for printi

2.1 Multi regression model

The response function representing any of the weld bead dimensions can be expressed as y=f (Q, F).The
relationship selected, being second degree response surface, is expressed as follows [12]: Y=b0+ b1Q+
b2F+ b3Q2+ b4F2+ b5QF.Where Q=Heat input, F=Wire feed rate.

Table No.- 2: Regression coefficients of model

Sl.No. Coefficient For the For the case of For the

case of Reinforcement case of
Penetration Height Width
1 b0 6.9714 1.2218 88.1254
2 b1 0.0601 0.0852 2.6686
3 b2 -0.1081 -0.0111 -2.1975
4 b3 0.0079 -0.0016 0.1816
5 b4 0.0008 0.0001 0.0161
6 b5 -0.0015 0.0000 -0.0708

2.1.1Development of Mathematical Model

The developed mathematical models are given below.

Penetration,mm=6.9714+0.0601Q0.1081F+0.0079Q2+0.0008F2-0.0015QF (1)
2800 Aniruddha Ghosh et al. / Procedia Engineering 10 (2011) 2797–2802

Reinforcement height, mm=1.2218+0.0852Q-0.0111F-0.0016Q2+0.0001F2 (2)

Width of weld bead, mm=88.1254+2.6686Q-2.1975F+0.1816Q2+0.0161F2-0.0708QF (3)
These mathematical models furnished above can be used to predict bead geometry by substituting the
values of the respective process parameters.

2.1.2Conducting conformity test

To determine the accuracy of the mathematical models developed, conformity test runs were conducted
with same experimental setup. After collecting experimental results a comparison was made between the
actual and predicted values of bead parameters, and the results are 97% accurate.

2.2Prediction of yield parameters through NEURO 3 software

By applying NEURO3 SOFTWARE, prediction parameters of SAW process have been done. Error
calculation is tabulated below.

TABLE 3:% of error for prediction through neural network

For the case For the case of For the
of Reinforcement case of
Penetration height Width
3.66 5.94 3.70
-1.32 6.49 -0.98
4.09 7.84 3.21
4.26 4.35 -1.82
-0.10 0.00 0.98
-1.34 -1.31 -6.02
2.10 1.97 -4.03
-2.27 0.00 -8.70

2.3Prediction of yield parameters through Graphical technique

Graphically Predicted Technique is a new and very simple technique; previously it was not seen in any
literature. It is a more appropriate technique w.r.t regression and neural networks model. In this technique
by taking input variables with in their range at first values of out put variables have been found out. Then
it has been graphically plotted with the help of MATLAB-7. By clicking on these graphs, values of
variables can be derived very quickly.
 Aniruddha Ghosh et al. / Procedia Engineering 10 (2011) 2797–2802 2801

Fig.1: Change of penetration w.r.t change of input variable

Fig.2: Change of Reinforcement height w.r.t change of input variables

Fig.3: Change of width w.r.t change of input variable

2802 Aniruddha Ghosh et al. / Procedia Engineering 10 (2011) 2797–2802

Values of input & output variables have some limit. Limit of output variables can be detected through this
graphically prediction technique. For any welding machine, input parameters have some range. Beyond
this range, a particular machine cannot work, it is practically true, but theoretically variables values can
be calculated beyond these limits. The output parameters values beyond the input variable values range
can be calculated through multi regression method, artificial neural networks, but they have no practical
visibility. Suppose output variable value is selected, whose corresponding input variables values are
beyond the range of input variables. So it is not applicable. In this method, the range of possible output
variables can be predicted and corresponding input variables values can be easily predicted, so there is no
chance of the above- mentioned mistake in this method. This graphically prediction technique gives
maximum, minimum range of possible output and input variables, side by side just clicking on the graphs
idea of variables can be formed quickly and accurately. It is the main advantage, distinctive from other
techniques of this method.

Conclusion
The performance of the developed system has been tested experimentally by for certain welding
conditions for a particular bead dimension. The experimental data proved a clear correlation between
welding parameters and the weld bead dimensions, and showed the geometrical features. The neural
network model is capable of making bead geometry prediction of the real-time quality control based on
observations of bead geometry and for on-line welding process control. In this paper a graphically
prediction technique has been described, which is able to give maximum, minimum range of possible
output and input variables, side by side just clicking on the graphs an idea of variables can be available
quickly and accurately. It is the main advantage, different from other device of this method.

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