An Optimization Design for Coefficient of Weld Reinforcement in Rapid Prototyping Based on Robotic Pulse MAG Forming

Abstract

During the process of rapid prototyping based on robotic pulse MAG forming, the coefficient of weld reinforcement is crucial to the geometric accuracy and mechanical property of metallic parts. The orthogonal design method, as well as the range analysis and variance analysis, were applied in this article to study the effects of wire feed rate, welding speed, pulse correction and arc length correction on coefficient of weld reinforcement, finding out the factors which were significant to the coefficient of weld reinforcement and optimizing the process parameters. The experimental results show that the order of the significance of parameters is as following: the welding speed, the arc length correction, the wire feed rate, and the pulse correction. Among them, the welding speed and arc length correction have the greatest influence on the coefficient of weld reinforcement, as is 0.025. The optimal process parameters are: arc length correction 8%, welding speed 14mm/s, wire feed rate 7.2m/min and pulse correction 0. At the same time, the coefficient of weld reinforcement is between 2.94 and 3.00, as the degree of confidence is 97.5%.