Quality variation in resistance spot welding is a major concern in the automotive industry. The relationship between weld quality and various process conditions, including abnormal process conditions, has not yet been systematically studied. This paper investigates this relationship using a newly developed two-stage, sliding-level experiment. In the experiment, welding current is treated as a “slid factor” whose settings are determined based on those of other process variables. Engineering knowledge is applied in statistical model selection. From the analysis, it is found that abnormal process conditions, such as axial misalignment, angular misalignment, poor fitup, edge weld, and electrode wear, significantly affect weld size and thus cause large variation in the weld quality. Although they may help increase the weld size in some cases, abnormal process conditions generally lead to a less robust process. In order to minimize the effects of the abnormal process conditions, a robust parameter design is formulated using the statistical models developed from the experimental data. The analysis suggests that high current and large electrodes should be used for reducing the weld quality variation. Developed in this study, the new experimental design and analysis procedures can also be applied to other processes, where the process variables are inter-dependent.
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August 2001
Technical Papers
Statistical Investigation on Resistance Spot Welding Quality Using a Two-State, Sliding-Level Experiment
Wei Li,
Wei Li
Department of Mechanical Engineering, University of Washington, Seattle, WA 98195-2600
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Shaowei Cheng,
Shaowei Cheng
Institute of Statistical Science, Academia Sinica, Taipei, Taiwan
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S. Jack Hu,
S. Jack Hu
Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109
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Justin Shriver
Justin Shriver
Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109
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Wei Li
Department of Mechanical Engineering, University of Washington, Seattle, WA 98195-2600
Shaowei Cheng
Institute of Statistical Science, Academia Sinica, Taipei, Taiwan
S. Jack Hu
Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109
Justin Shriver
Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 2000; revised Dec. 2000. Associate Editor: E. DeMeter.
J. Manuf. Sci. Eng. Aug 2001, 123(3): 513-520 (8 pages)
Published Online: December 1, 2000
Article history
Received:
April 1, 2000
Revised:
December 1, 2000
Citation
Li, W., Cheng, S., Hu , S. J., and Shriver, J. (December 1, 2000). "Statistical Investigation on Resistance Spot Welding Quality Using a Two-State, Sliding-Level Experiment ." ASME. J. Manuf. Sci. Eng. August 2001; 123(3): 513–520. https://doi.org/10.1115/1.1382595
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