Reducing Stud Welding Process Variability by Experimental Design: A Systematic Approach for Process Optimization

Design of Experiment (DOE) is a structured and organized method to determine relationships between factors affecting and output of a process. This thesis shows how process optimization can be achieved in two methods; A first method using Taguchi experimental design methodology process control in order to confirm the three specified factors that are critical to the stud arc welding operation. The design plan is based on the use of orthogonal arrays introduced by Taguchi. A second method of optimization is by applying the mathematical exercise of Non-linear “Artificial Neural Network”. The reduction in standard deviation was approximately (30.06 per cent) and for the range the reduction was as approximately (29.39per cent). In the other side the increase in the tensile strength mean was as approximately (30.84 per cent). The parameters that affect the tensile strength of their influence, the factor welding time have an major effect on stud welding process, followed by factor sheet coating and factor stud material.