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Album: Public (Jeff_Perkinson)

by Community Manager Jeff_Perkinson Community Manager
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Figure 1b - A partial view of the inner part of the machine. Head and tail of the two plates will be cut by laser technology and then welded together.
Figure 1a - External view of the heavy laser welder containment at Montbrison workshop. The size of the door gives an idea of the dimensions of this industrial welder.
Figure 1a –  An external view of the containment of the heavy laser welder at Montbrison workshop. The size of the door gives an idea of the dimensions of this industrial welder.
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Figure 2 – Welding flaws map JMP Chart Builder is used to view the weld defect map. The major defect areas can easily be recognized: partial penetration (yellow), holes (orange), spatters (blue, purple), chain of pearls (horizontale stripes), defect-free area (black). Pictures of the top and bottom weld seam are displayed in the tooltip area when moving the mouse over.
Figure 3 – Base material strength analysis The dashboard is composed of various JMP platforms: Graph Builder, Distributions and ANOVA. The custom map shape[1] of the Graph Builder displays the two samples corresponding to each of the two plates and the position of the various cupping tests colored by strength. In the ANOVA, the overlap of the two diamond tips demonstrates that the plate can be considered as identical. The chart on the right shows that the strength variance is higher on operator side (OS). Once aggregated, data from the bottom distribution presents an average strength is 9.76±0.18 tons (at 2σ).
Figure 3 – Base material strength analysis The dashboard is composed of various JMP platforms: Graph Builder, Distributions and ANOVA. The custom map shape[1] of the Graph Builder displays the two samples corresponding to each of the two plates and the position of the various cupping tests colored by strength. In the ANOVA, the overlap of the two diamond tips demonstrates that the plate can be considered as identical. The chart on the right shows that the strength variance is higher on operator side (OS). Once aggregated, data from the bottom distribution presents an average strength is 9.76±0.18 tons (at 2σ).
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Figure 4 – Appearance of the plate – The plates present a relatively flat aspect on the drive side and waves on the operator side. The history of the plates is unknown but there must have been a rolling of planishing issue with a higher force applied on the operator side, which created this appearance and a periodic modification of the strength.
Figure 5 – Building of the custom design of experiments – The Custom Design platform allows the creation of a completely customized test plan. The Responses part provides the list of responses to be optimized, in this case the goal is to look for the maximum strength. The Factors part presents the way how the four constraints have been addressed. As the position is uncontrolled, no values are input into the limits. The Model part displays all the factors and interactions considered in the model. RSM (Response Surface Methodology) is used, the interactions between the laser power, the welding speed and the side have been removed as they have been considered not significant. Finally, the Design Generation part proposes 8 trials and 24 measurements.
Figure 6 – Building of the custom design of experiments –  The results are presented into a dashboard. The irregular shape of the weldability lobe is reminded in the top right chart. The experimental points, proposed by the Custom Design platform, and the associated strength values, in percent, are summarized in the bottom right chart. Finally, the Fit Model platform on the left displays the modeling result. An explicative power R2 of 96% has been reached, meaning that only 4% of the variations escape its predictive power. The Effect Summary shows that the main effects (laser power, welding speed and position) are significant. The side factor is not directly significant, but becomes so when associated with the position. The VIFs (Variance Inflation Factors, not displayed here) have all a value smaller than 1.6, showing no multicolinearity issue (no linear relationship among two or more explanatory variables exists).
Figure 7 – Checking the model's behavior with the Profiler –  The upper profiler refers to low position values, the lower to high position values. The model response (strength in %) is shown on the y- axis, the factors on the x-axis. Weld after weld (increasing position), the strengthes on the DS and C sides remain mostly unchanged while the strength on the OS side changes dramatically, as observed visually. This phenomenon being well modeled, it is now possible to access the pure effects of laser power and welding speed. The weld strength increases when the laser power decreases and the traveling speed increases.
Figure 8 – Optimization with the Contour Profiler –  The Contour Profiler displays the welding speed on the x-axis and the laser power on the y-axis, with the position and side values fixed. Arbitrarily, the side value was set to DS. As for the position, it was set to the latter. The weldability lobe where the weld bead is free of defects was reproduced in black using a script and the polygon drawing function.The iso-resistance curves of the model, in red, are also plotted. The associated resistance percentages are also displayed in red. The welding speed and laser power sliders are set to the coordinates of the optimal point, materialized by the black cross in the center of the graph.
Figure 9 – Optimum preset and weld seam appearance –  The figure shows the upper (left) and lower (right) weld bead facies. The latter are free of the main welding defects.
Figure 10 – Optimum preset and weld strength –  The figure shows the results of the 3 Erichsen-type cupping tests performed on the DS, C and OS sides. Visually, it can be seen that it is the material that breaks and not the weld. Moreover, all the tests show a strength level comparable to the base material one.
Figure 11 – Clecim SAS (Montbrison city, France)
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Figure 4 – Appearance of the plate –  The plates present a relatively flat aspect on the drive side and waves on the operator side. The history of the plates is unknown but there must have been a rolling of planishing issue with a higher force applied on the operator side, which created this appearance and a periodic modification of the strength.
Figure 2 – Welding flaws map –  JMP Chart Builder is used to view the weld defect map. The major defect areas can easily be recognized: partial penetration (yellow), holes (orange), spatters (blue, purple), chain of pearls (horizontale stripes), defect-free area (black). Pictures of the top and bottom weld seam are displayed in the tooltip area when moving the mouse over.
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Optimum 3
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Added ‎07-18-2022 09:25 AM
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Optimum 3
Posted in: Re: DOE - "Reverse" model - ( ‎07-18-2022 08:31 AM )

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