Integration of Robust Design and Simulation to Predict Optimum Parameters for Laser Beam Welding

In this paper, an attempt is made to achieve a robust weld quality that is insensitive to uncontrollable factors. The best process parameters are identified by integrating the Robust Design Concept and simulation. The influence of process parameters on Laser Beam Welding are studied The controllable parameters considered are heat flux, welding speed, focus diameter and plate thickness. The ambient temperature is taken as uncontrollable factor. Simulation of Experiments is performed for different combinations of parameter using ANSYS software based on Taguchi's Robust technique. Three dimensional non-linear transient thermal analysis is performed and the temperature distribution along the laser welded plate is obtained in the form of contour plots. Bead width and penetration depth are determined from these plots. To find the effect of control factors on the responses, ANOVA table is formed. Also, the best parameters for different responses are identified using S/N curves.