An On-Line ANN-Based Approach for Quality Estimation in Resistance Spot Welding

Abstract:

The aim of this study is to develop an effective on-line ANN-based approach for quality estimation in resistance spot welding. The proposed approach examines the welding parameters and conditions known to have an influence on weld quality, and builds a quality estimation model step by step. The modeling procedure begins by establishing relationships between welding parameters (welding time, welding current, electrode force and sheet metal thickness), welding conditions represented by typical characteristics of the dynamic resistance curve and welding quality indices (nugget diameter, nugget penetration, and indentation depth), and the sensitivity of these elements to the variation of the process conditions. Using these results and various statistical tools, three estimation models are developed. The first one is based exclusively on welding parameters. The second model is based on characteristics of the dynamic resistance curve. The third estimation model combines welding parameters and characteristics of dynamic resistance curves. In order to carry out the models building procedure, an extensive number of welding experiments are required. For this purpose, Taguchi’s efficient method of experimental planning is adopted. The results demonstrate that the developed models can provide an accurate on-line estimate of the weld quality, under different welding conditions.

• Periodical: Advanced Materials Research (Volume 112)
• Pages: 141-148
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.112.141
• Online since: May 2010
• Authors: Abderrazak El Ouafi, Rudy Bélanger, Jean-François Méthot
• Keywords: Artificial Neural Network (ANN), Dynamic Resistance, Resistance Spot Welding (RSW), Weld Quality

References

[1] A. Stiebel, C. Ulmer, D. Kodrack and B. Holmes: Monitoring and control of spot weld operations, SAE Technical Paper, No. 860579, International Congress and Exposition, Detroit, Michigan, (1986).

DOI: 10.4271/860579

[2] R.W.J. Messler and M. Jou: Review of control systems for resistance spot welding: past and current practices and emerging trends, Science and Technology of Welding and Joining, 1(1996) 1.

DOI: 10.1179/stw.1996.1.1.1

[3] H. Zhang and J. Senkara: Resistance welding: fundamentals and applications, CRC Press, Taylor & Francis Group, (2006).

[4] A. Klimpel: Investigation and quality control of resistance spot welding, Welding International, 3 (1989) 12.

DOI: 10.1080/09507118909449077

[5] C.S. Chien and E. Kannatey-Asibu Jr.: Investigation of monitoring systems for resistance spot welding, Welding Journal, 9 (2002) 81.

[6] S.A. Gedeon, C.D. Sorensen, K.T. Ulrich, T.W. Eagar: Measurement of dynamic electrical and mechanical properties of resistance spot welds, Welding Journal, 12 (1987) 66.

[7] W.L. Roberts: Resistance variations during spot welding, Welding Journal, 11 (1951) 30.

[8] S. Bhattacharya, D.R. Andrews: Significance of dynamic resistance curve in the theory and practice of spot welding, Welding and metal fabrication, 8 (1974) 42.

[9] D.W. Dickinson, J.E. Franklin, A. Stanya: Characterization of spot welding behaviour by dynamic electrical parameter monitoring, Welding Journal, 6 (1980) 59.

[10] W. Li, S.J. Hu, J. Ni: On-line quality estimation in resistance spot welding, Journal of manufacturing science and engineering, 122 (2000) 3.

[11] Y. Cho, S. Rhee: $ew technology for measuring dynamic resistance and estimating strength in resistance spot welding, Measurement Science and Technology, 11 (2000) 8.

DOI: 10.1088/0957-0233/11/8/311

[12] Y. Cho, Y Kim, S. Rhee: Development of a quality estimation model using multivariate analysis during resistance spot welding, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 215 (2001) 11.

DOI: 10.1243/0954405011519439

[13] S.R. Lee, Y.J. Choo, T.Y. Lee, M.H. Kim, S.K. Choi: A quality assurance technique for resistance spot welding using a neuro-fuzzy algorithm, J. of Manuf. Systems, 5 (2001) 20.

DOI: 10.1016/s0278-6125(01)80051-0

[14] E. Haapalainen, P. Laurinen, H. Junno, L. Tuovinen and J. Röning: Methods for Classifying Spot Welding Processes - A Comparative Study of Performance, 18th Int. Conf. on industrial and engineering applications of artificial intelligence and expert systems, 3533 (2005).

DOI: 10.1007/11504894_58

[15] L. Yi, L. Jinhe, X. Huibin, X. Chengzhi and L. Lin: Regression modeling and process analysis of resistance spot welding on galvanized steel sheet, J. of Materials & Design, 30 (2009) 7.

DOI: 10.1016/j.matdes.2008.09.031

[16] M. Zhou, H. Zhang and S.J. Hu: Relationship between quality and attributes of spot welds, Welding Journal, 82 (2003) 4.

[17] H. Rowlands and F. Antony: Application of design of experiments to a spot welding process, Journal of Assembly Automation, 23 (2003) 3.

DOI: 10.1108/01445150310486549