Weld quality improvements using parameter design approach

Other conference contribution, 2011

In this study the change in pre-conditions for quality/inspection are studied when the performance of an existing robotised welding process is improved using parameter design from robust design methodology. The findings are several. First, it was found that it is possible to build empirical response surface models of the key performance indicators that serve to improve the chances to find settings in the welding geometry that fulfil all requirements without increasing production cost. Secondly, modelling of welding processes, in contrast to most processes, requires high resolution experimental plans since many multi parameters interactions are active. Indicating very complex response surfaces. Thirdly, it was also found that basic industrial standard gauges and procedures for weld quality inspection easily are out-dated if not care is taken to investigate and improve all measurement systems used relative the actual variations occurring in the production. Fourthly, improved welding performance in production will change pre-conditions for both product development and quality surveillance facilitating evolution of interdisciplinary co-operation.