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[27] HUTT, G. A. , LUCAS, W. Arc disturbances in consumable electrode welding - a review of the literature. The Welding Institute, Research Report 173/1982. [28] RODWELL, M. H. A preliminary investigation into arc disturbances and poor weld appearance in the spray transfer MIG welding of stainless steel. The Welding Institute, Research Report 273/1985. [29] LUIJENDIJK, T. and HERMANS, M. J. M. Short circuiting GMA welding with Ar-CO2 gas mixtures. Welding Review International, 15(3), August 1996,91,94-95. [30] OUDEN, G. den, )CIAO, Y. H. , HERMANS, M. J. M. The role of weld pool oscillation in arc welding. International Journal for the Joining of Materials, 5(4), 1993,123-129. [31] HERMANS, MINI., SIPKES, M. P., OUDEN, G. den Characteristic features of the short circuiting arc welding process. International, 12(2), 1993,80-86. Welding Review [32] KIM, J. -W. and NA, S. -J. A study on the effect of contact tube-to- workpiece distance on weld pool shape in gas metal arc welding. Welding Journal, 74(5), May 1995,141 s-152s. [33] LIU, S. , SIEWERT, TA Metal transfer in gas metal arc welding: droplet rate. Welding Journal, 68(2), 1989,52s-58s. [34] GUPTA, S. R. and GUPTA, P. C. Effect of some variables on spatter loss. Welding and Metal Fabrication, 52(9), November/December 1984,361- 362,364. [35] OGTJNBIYI, T. E. B. and NORRISH, J. GMAW metal transfer and arc stability assessment using monitoring indices. IN: TWI Conference on Computer Technology in Welding, 9-12 June 1996, Lanaken, Belgium, Paper 11. [36] NEEDHAM, J. C. Control in short-circuit MIG arc welding. IN: TWI International Conference on Advanced Welding Systems, 19-21 Nov. 1985, London, 331-339. [37] MITA, T. , SAKABE, A. , YOKOO, T. The estimation of arc stability on CO2 gas shielded arc welding. IN: TWI International Conference on Advanced Welding Systems, 19-21 Nov. 1985, London, 261-271. 203
[38] D1LTHEY, U. , REICHELL, T. , SCHELLER, W. Statistical process parameter surveillance in GMA welding. International Journal for the Joining of Materials, 8(3), 1996,120-126. [39] SHINODA, T. , NISHIKAWA, H. Monitoring and signal processing of " short circuiting metal transfer of metal active gas welding process. IN: JOM-7 International Conference on the Joining of Materials. 31 May -2 June, 1995, Helsingor, Denmark, 558-565. [40] SHINODA, T. , NISHIKAWA, H. , SHIMIZU, T. The development of data processing and assessment of arc stability as affected by the titanium content of GMAW wires during metal transfer. IN: TWI Conference on Computer Technology in Welding, 9-12 June, 1996, Lanaken, Belgium, Paper 57. [41] DYURGEROV, N. Bridge rupture between electrode and molten pool. Welding Production, 19(3), 1972,5-8. [42] LEBEDEV, V. et al. On technological (welding) properties of power sources for arc welding. IIW Doc. USSR Academy of Sciences, USSR National Welding Committee, 1979. [43] LIPEI, J. et al. The effect of the dynamic behaviour of welding rectifiers on spatter. Welding International, 2(3), 1988,263-268. [44] LEBEDEV, V. , SIDOREIKO, M. The technological features of rectifiers for manual arc welding. Automatic Welding, 16(7), 1963,64-68. [45] JENNINGS, C. Dynamic characteristics of DC welding machines. Welding Journal, 30(2), February 1951,117-138. [46] LEBEDEV, A. Optimisation of parameters of the welding circuit in mechanised CO2 welding. Paton Welding Journal, 1(1), 1989,36-39. [47] VOROUIN, R. , GOLOSHCAPOV, S. Evaluating the thin wire gas shielded arc welding process. Welding Production, 16(9), 1969,51-55. [48] POPKOV, A. et al. Reducing the spatter of liquid metal in CO2 welding by means of optimisation of the welding parameters. Welding Production, 24(3), 1977,26-27. [49] NEEDHAM, J. Evolution of power sources in arc welding - transition from passive to active role. TWI Research Bulletin, 28(4), April 1987,113-118. [50] GUPTA, S. et al. Application of statistical analysis for process stability evaluation in GMA welding. IIW Doc. 212.710-88,1988. 204
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CRANFIELD UNIVERSITY GC CARVALHO AN
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ABSTRACT The aim of this work was t
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I dedicate this work to the memory
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FIGURES TABLES APPENDICES NOTATION
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3.3.2.1 Welding parameters generato
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References Further reading Appendic
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Figure 3.12 Offsets for weld start
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Figure 6.31 Voltage step input test
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Figure J. 2 Plot of stand-off varia
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Table A. 1 Welding extended entity
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NOTATION A, Electrode sectional are
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Pr(ign) Possibility measure of proc
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1. Introduction Welding is the thir
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Chapter 4 describes the on-line pos
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In pulse transfer, the welding curr
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Pd = Pv - pzh-s (2.1) where Pd is t
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the bridge. Another factor that ind
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establish the stable conditions for
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Philpott [ref. 21] developed an on-
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current peak at the moment the tip
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obot on the line must be individual
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collision detection capabilities wh
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cause dynamic variation in the seam
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Another type of robot static calibr
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spatter the gas nozzle is particula
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Table 2.1: Joint positioning tolera
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In order to minimise the undesirabl
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c) Ultrasonic sensors; d) Through-t
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where K,, K2, K3 and K4 are constan
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Philpott [refs. 21,131], based on t
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centre. This is attributed to the m
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technique must be employed to preve
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" digital hardware, which is basica
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" Maximum value, W.: Wmý = max(W )
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process studied over a small range.
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In-process welding control is a muc
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volume caused by the presence of a
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SHIELDING GAS IN CONSUMABLE ELECTRO
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Arc voltage Anode Arc length I Anod
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computed ideal procedure optimisnti
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CONSTANT CURRENT POWER SOURCE `j' O
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Original Surface New Surface Electr
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otating welding wire direction weld
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3.1.1.1 Robot errors A robot arm is
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3.2.2 Programming error correction
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3.3.2 Off-line programming module I
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Pen is the weld penetration (side p
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a. 2) Geometrical constraints from
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Step 11 Step 12 Step 13 Step 14 Ste
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Step 21 Step 22 If the wire feed sp
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the Y'-axis results in a positive "
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_ p1e0a - pORoba m31 Ilp! - poll (3
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of a robot in its zero position12 w
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frame points to the front of the ro
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CAD Off-line (AutoCAD) programming
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Z Surface 4 A Y 7 M2 Open Edge Join
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WCF World Co-ordinates Frame 2a = J
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x Torch Co-ordinates Frame o Indica
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vo Ö 't7 Y7 't O m O 'S O O S O S
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ýý aý 0 oA aW ö A O Zt A OO 't
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Ti 9ý-! i4 *Tx t ap31 jx ý- ymin
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errors', (i. e. joint positioning,
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was considered to be outside the sc
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Table 4.3 - Linguistic representati
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The introduction of such a reduced
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Table 4.8 - Final welding process c
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the collection of welding data corr
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Step 4- Calculate the confidence of
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Z Table Co-ordinates Frame Y X Robo
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5.3 Monitoring system The monitorin
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the torch end. Only one degree of f
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Current: 500 Position: 234.5 5.7.3
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I" va JI ºr ö C 3 r" r" rl f_ £-
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IgurC a. H -I UI qur vCiSUJ JpCCU C
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126
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Table 6.1 - Welding trials carried
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Table 6.3 - Coefficients of Ogunbiy
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Note that the calibration model sho
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Table 6.6 - Welding parameters used
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constant set-up welding parameters
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stickout lengths and the temperatur
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of the dip mode of metal transfer.
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which would become active by settin
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In section 4.2.5 it has been mentio
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300 280 260 240 rd 35- 3D 25 20 15
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Figure 6.5 - Measured "versus" Pred
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i S 0 -0.1 -0.2 -0.3 -0.7- 68 10 12
Page 177 and 178: 32.0 E 31.5 y 31.0 30.5 30.0 j 29.5
Page 179 and 180: 35 - 30 p 15 10 0.00 2.60 5.42 8.23
Page 181 and 182: 40 35 30 25 20 15 10 A+iIII+F0.17 2
Page 183 and 184: 30 28 26 24 22 SO_act [mm] DipR [mo
Page 185 and 186: 22 20 18 SO_act [mm] DipR [ohm/100]
Page 187 and 188: !: 30 25 20t 10 5-- 0 Dip Transfer
Page 189 and 190: 0.430- - 0.380- - :r 0.330 fPR L- 0
Page 191 and 192: 7.2 Tests with varying stand-off an
Page 193 and 194: Table 7.3 - Bead geometry along the
Page 195 and 196: ö a2 ., u" u,.., g .,. aucyuaac VI
Page 197 and 198: 0 24-- 22-- 18 210 1 90 0 v 170 mm
Page 199 and 200: Q 34 32 3o mIm Viewing direction Fl
Page 201 and 202: ýa 34 mm JO a .. ý nn ýr "u 00 M
Page 203 and 204: 22 20 18 Viewing direction Flange W
Page 205 and 206: 36 33 31 o 29 t 350 310 o 290 U due
Page 207 and 208: I C, x -i 23 21 j 19 Q 240c WFS =10
Page 209 and 210: en 34 32 - vsec 30- 26- 24 + .. ++
Page 211 and 212: 186
Page 213 and 214: " to design and build the hardware
Page 215 and 216: Although only linear joints were im
Page 217 and 218: for predicting possibility of bad a
Page 219 and 220: 8.4 Process monitoring and control
Page 221 and 222: satisfy the required quality criter
Page 223 and 224: 198
Page 225 and 226: types of joints and multi-pass weld
Page 227: [14] NEMCHINSKY, V. A. The effect o
Page 231 and 232: [64] KING, F-J. and HIRSCH, P. Seam
Page 233 and 234: [86] CARGNELLI, M. and ROGOWSKI, A.
Page 235 and 236: [109] KURKIN, N. S. and DRIKKER, V.
Page 237 and 238: [130] USHIO, M. , LIU, W. , MAO, W.
Page 239 and 240: [151] DAVIS, A. R. Orr-line gap det
Page 241 and 242: [177] COOK, G. E. Feedback and adap
Page 243 and 244: [201] WON, Y. J. and CHO, H. S. A f
Page 245 and 246: 220
Page 247 and 248: 222
Page 249 and 250: wnum: local variable which defines
Page 251 and 252: Table A. 1 - continuation List item
Page 253 and 254: Imean = a2 + b2*WFS + c2*SO + d2*SO
Page 255 and 256: TCP2 number are also defined. The o
Page 257 and 258: f ROBSET. DAT: This file is created
Page 259 and 260: Figure C. 3 - Main dialogue box of
Page 261 and 262: Choose the set of welding parameter
Page 263 and 264: Water Cooling optic fibre bundle 0
Page 265 and 266: Figure E. 1 - Main graphical screen
Page 267 and 268: 242
Page 269 and 270: Table G. 2 - Interface box external
Page 271 and 272: Robot ii Controller +24W CO . +24Vd
Page 273 and 274: 248
Page 275 and 276: Table 1.1 - continuation Run Vpk M
Page 277 and 278: 10- y =0.001ac 0 r. dSO [mm] $0 '10
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5.00- 0.00 y=0.0019x 1000 1500 2000
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Table J. 7 - Welding data collected
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Table J. 10 - Welding data collecte
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20.00- 15. M y=0.0047x - 1.7922 10.
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266
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Table K. 1- continuation Set-up par
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Table K. 1 - continuation Set-up pa
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Table K. 2 - continuation Set up pa
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Table K. 2 - Continuation Set-up pa
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Table K. 3 - Continuation Set-up pa
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Table K. 3 - Continuation Setup par
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