Model Development for Prediction and Evolution of the Parametric Dependence of Bead Volume in Submerged Arc Butt Welding

A nonlinear mathematical model has been aimed to develop, for prediction as well as estimation of the parametric dependence of bead volume in submerged arc butt welding. Based on factorial design without replication, experiments have been performed with three different levels of process parameters like welding current, electrode stick out and voltage to obtain butt joints from Mild Steel plates. Parameters associated with bead geometry like bead width, reinforcement, depth of penetration etc. have been measured for each experimental runs. By incorporating certain assumptions on the bead geometry and assuming unit length of the work piece, bead volumes have been calculated. All the data thus obtained have been utilized to develop a nonlinear mathematical model for prediction of bead volume at different settings of factor level. The adequacy of the developed model have been tested by ANOVA (Analysis of Variance Method). Finally the effect of process variables on bead volume of the weldment have been determined quantitatively and represented graphically. The study reveals that all the selected process variables have positive effect on bead volume.