Variation Causes Analysis Attributed to Different Metrological Instruments to Verify the Geometric Characteristics of a Spot Welding Process

Almeida, Fabrício Alves de; Gomes, José Henrique de Freitas; Gomes, Guilherme Ferreira; Romão, Estevão Luiz; Balestrassi, Pedro Paulo

doi:10.1590/0104-9224/SI2304.05

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Artigos Técnicos • Soldag. insp. 23 (4) • Dec 2018 • https://doi.org/10.1590/0104-9224/SI2304.05 copy

Variation Causes Analysis Attributed to Different Metrological Instruments to Verify the Geometric Characteristics of a Spot Welding Process

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

In this study, we sought to analyze the variability of instruments used in industry to evaluate the geometric characteristics of a welding point. For this purpose, the design of experiments technique was used to generate a fractional factorial design for the welding parameter configurations in test specimens of hot dip galvanized steels in order to represent the real amplitude of the resistance spot welding process. For the analyzes, the repeatability and reproducibility (GR&R) study was used by the analysis of variance method to identify the variation components of the measurement system by evaluating three different instruments, comparing the measurements performed by an image analyzer, from the metallography and measurements of conventional metrology instruments such as the dial-gauge and the caliper. Two quality characteristics were evaluated: indentation depth and nugget width. From the results it was possible to verify that the image analyzer presented a lower variability in the measurements, being the best choice for the measurements of the quality responses of the spot welding process, presenting a GR&R classified as acceptable.

Key-words:
Indentation depth; Nugget width; Measurement system analysis; GR&R; Variability

Sistema de Medição	%GR&R
Aceitável	< 10%
Marginal	10% - 30%
Inaceitável	> 30%

		Com interação	Sem interação
Processo	=	${\hat{σ}}_{α}^{2} = \frac{M Q P - M Q P O}{o r}$	${\hat{σ}}_{α}^{2} = \frac{M Q P - M Q E}{o r}$
Repetitividade	=	${\hat{σ}}_{ε}^{2} = M Q E$	${\hat{σ}}_{ε}^{2} = M Q E$
Reprodutibilidade	=	${\hat{σ}}_{β}^{2} + {\hat{σ}}_{α β}^{2} = \frac{M Q O - M Q P O}{p r} + \frac{M Q P O - M Q E}{r}$	${\hat{σ}}_{β}^{2} = \frac{M Q O - M Q E}{p r}$
Sistema de Medição	=	${\hat{σ}}_{repetitividade}^{2} + {\hat{σ}}_{reprodutibilidade}^{2}$	${\hat{σ}}_{repetitividade}^{2} + {\hat{σ}}_{reprodutibilidade}^{2}$
Variação Total	=	${\hat{σ}}_{P}^{2} + {\hat{σ}}_{M S}^{2}$	${\hat{σ}}_{P}^{2} + {\hat{σ}}_{M S}^{2}$

Parâmetros	Unidade	Níveis trabalhados
Parâmetros	Unidade	-1	+1
T _{pré-aquecimento}	[Ciclos]	5	11
I _{pré-aquecimento}	[%kA]	66	74
T _soldagem	[Ciclos]	7	17
I _soldagem	[%kA]	75	83

N	Configuração de entrada
	*T_{pré-aquecimento}*	*I_{pré-aquecimento}*	*T_soldagem*	*I_soldagem*
	*(ciclos)*	*(%kA)*	*(ciclos)*	*(%kA)*
1	11	74	7	83
2	11	66	17	83
3	5	74	7	83
4	11	74	7	75
5	5	66	17	83
6	11	66	17	75
7	5	74	17	83
8	11	74	17	83

p	o	*Análise por imagem - PI*					*Análise por imagem - DP*					*Relógio Apalpador*			*Paquímetro*
p	o	r = 1	r = 2		r = 3		r = 1	r = 2		r = 3		r = 1	r = 2	r = 3	r = 1	r = 2	r = 3
1	A	0.1910		0.2023		0.1919	4.2946		4.2741		4.3528	0.1400	0.1200	0.1700	5.4000	5.3000	5.3000
1	B	0.2021		0.1909		0.2016	4.3239		4.3246		4.2935	0.2000	0.2000	0.2000	5.1000	5.1000	5.2000
1	C	0.2010		0.1916		0.1912	4.3440		4.3542		4.3542	0.1800	0.1800	0.1300	5.4500	5.4500	5.4500
1	D	0.1915		0.1908		0.1921	4.3843		4.3542		4.3843	0.2000	0.1900	0.2100	5.5000	5.7000	5.8000
2	A	0.2107		0.2116		0.2117	4.6539		4.7241		4.7844	0.1300	0.0500	0.1100	4.4000	4.4500	4.4000
2	B	0.2021		0.2122		0.2211	4.7436		4.7246		4.7544	0.1050	0.2100	0.2000	4.2500	4.3500	4.4000
2	C	0.2120		0.2222		0.2220	4.7342		4.7248		4.7335	0.2000	0.1800	0.0800	4.5500	4.5500	4.5500
2	D	0.2117		0.2016		0.2118	4.7243		4.8439		4.8544	0.1800	0.1700	0.2000	4.8500	4.8000	4.6500
3	A	0.1314		0.1214		0.1227	3.5340		3.6637		3.6440	0.1000	0.1000	0.1000	5.2000	5.2000	5.3000
3	B	0.1333		0.1217		0.1215	3.6045		3.6148		3.5648	0.2100	0.2100	0.2100	4.9000	4.7500	4.8500
3	C	0.1217		0.1214		0.1316	3.6448		3.6350		3.6444	0.1000	0.1000	0.1000	4.8000	4.8500	4.8500
3	D	0.1216		0.1310		0.1318	3.6741		3.6739		3.6546	0.1300	0.1400	0.1000	4.4000	4.4000	4.8000
4	A	0.0687		0.0723		0.0704	3.5444		3.5442		3.5643	0.0900	0.0700	0.0600	4.7500	4.8500	4.7000
4	B	0.0714		0.0691		0.0709	3.5745		3.5455		3.5344	0.1300	0.1300	0.1100	4.2000	4.3000	4.4500
4	C	0.0694		0.0689		0.0707	3.5343		3.5642		3.5138	0.1100	0.1200	0.1000	4.4500	4.5500	4.4500
4	D	0.0677		0.0718		0.0722	3.5251		3.5743		3.5743	0.1300	0.1200	0.1200	4.4000	4.1500	4.6000
5	A	0.2518		0.2524		0.2612	4.5848		4.5141		4.5237	0.1700	0.2100	0.1600	4.3000	4.4000	4.3000
5	B	0.2616		0.2612		0.2714	4.5540		4.5438		4.5639	0.2300	0.2800	0.2850	4.0500	4.1500	3.6000
5	C	0.2618		0.2511		0.2612	4.6136		4.6437		4.5847	0.1900	0.1200	0.1300	4.9000	5.0000	5.0000
5	D	0.2717		0.2711		0.2519	4.5336		4.5239		4.6239	0.2200	0.2200	0.2600	5.0000	4.6000	4.3000
6	A	0.2017		0.1918		0.2018	3.8045		3.7843		3.7950	0.1000	0.1500	0.1100	4.1000	4.0500	4.0500
6	B	0.1914		0.1915		0.2014	3.7946		3.8041		3.8246	0.2000	0.1500	0.1900	4.0000	4.1500	4.2000
6	C	0.2017		0.2013		0.2015	3.8439		3.8334		3.8341	0.1800	0.1800	0.0900	5.0000	5.1000	5.1000
6	D	0.2023		0.2019		0.1929	3.8439		3.8745		3.8744	0.2100	0.1600	0.1200	5.0000	5.2000	4.9500
7	A	0.1689		0.1715		0.1720	4.7939		4.8639		4.7944	0.1500	0.0600	0.1000	4.4000	4.4500	4.4000
7	B	0.1818		0.1715		0.1712	4.8237		4.8050		4.8139	0.3200	0.2000	0.2000	4.2000	4.3500	4.4000
7	C	0.1682		0.1725		0.1709	4.8346		4.8143		4.8248	0.1200	0.1400	0.1300	4.5000	4.6000	4.4500
7	D	0.1712		0.1638		0.1708	4.8144		4.9245		4.8441	0.2000	0.1500	0.2000	4.6500	4.9000	4.3000
8	A	0.1416		0.1430		0.1417	4.0739		4.1646		4.0846	0.1900	0.2700	0.2600	5.5000	5.4500	5.4500
8	B	0.1414		0.1410		0.1416	4.1445		4.1242		4.1339	0.3200	0.3300	0.3100	5.6500	5.7500	5.8000
8	C	0.1407		0.1421		0.1392	4.1841		4.1639		4.0938	0.1800	0.1800	0.1500	4.5500	4.6000	4.5000
8	D	0.1375		0.1415		0.1429	4.1243		4.1945		4.1841	0.3400	0.3200	0.3200	5.3500	5.1500	5.4500

*Amostra*	N	*Média*	*DesvPad*	*EP Média*
Relógio Apalpador	32	0.1696	0.0620	0.0110
Analysis Five	32	0.1719	0.0559	0.0099
Diferença Pareada	32	-0.0023	0.0709	0.0125
	Teste t da diferença das médias = 0 (vs ≠ 0)
t-value	-0.18
p-value	0.855

Fonte	*Analisador de imagem*		*Relógio Apalpador*
Fonte	ó	*% Contribuição*	ó	*% Contribuição*
ó_GR&R	0.0050865	8.63	0.0541768	76.31
ó_{repetitividade}	0.0050865	8.63	0.0315651	44.46
ó_{reprodutibilidade}	0	0	0.0440315	62.02
ó_operadores	0	0	0.0383582	54.03
ó_peça×_operadores	–	–	0.0216199	30.45
ó_{peça-a-peça}	0.0587189	99.63	0.0458871	64.63
ó_peça	0.0587189	99.63	0.0458871	64.63
ó_T	0.0589388	100	0.0709982	100
ndc	16		1

*Amostra*	N	*Média*	*DesvPad*	*EP Média*
Paquímetro	32	4.7542	0.4753	0.0840
Analysis Five	32	4.2034	0.4751	0.0840
Diferença Pareada	32	0.551	0.701	0.124
	Teste t da diferença das médias = 0 (vs ≠ 0)
t-value	4.44
p-value	0.000

Fonte	*Analisador de imagem*		*Relógio Apalpador*
Fonte	ó	*% Contribuição*	ó	*% Contribuição*
ó_GR&R	0.040278	8.04	0.369652	73.96
ó_{repetitividade}	0.033796	6.75	0.134145	26.84
ó_{reprodutibilidade}	0.021912	4.38	0.344453	68.92
ó_operadores	0.021912	4.38	0	0
ó_peça×_operadores	–	–	0.344453	68.92
ó_{peça-a-peça}	0.499109	99.68	0.336376	67.30
ó_peça	0.499109	99.68	0.336376	67.30
ó_T	0.500732	100	0.499792	100
ndc	17		1

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