International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-9 Issue-3, January 2020 2795 Published By: Blue Eyes Intelligence Engineering & Sciences Publication Retrieval Number: C9215019320/2020©BEIESP DOI: 10.35940/ijitee.C9215.019320 Abstract: This study was intended to optimize the resistance Spot Welding Parameters (RSW) of sheet metals joints. The variation parameters selected were electrode force, welding current and welding time of 1.2 mm thickness low carbon steel. The settings of process parameters were conducted according to the L9 Taguchi orthogonal array in randomized way. The optimum process parameter was then obtained by using signal to noise ratio and analyzed further on the significant level by using Analysis of Variance (ANOVA). The developed response has been found well fitted and can be effectively used for tensile shear strength prediction. The optimum parameters achieved were electrode force (2.3 kN), welding time (10 cycles) and welding current (8 kA). Based on the ANOVA, it was found that the electrode force is a vital parameter in controlling the tensile shear strength as compared to welding time and welding current. Keywords: Optimization, Resistance Spot Welding (RSW), Taguchi Method, ANOVA. I. INTRODUCTION The advantages of spot welding are its high speed and adaptability for automation in high rate or high volume engenderment. Despite these advantages, resistance spot welding (RSW) also has issues of quality inconsistencies from weld to weld [1]. It was found that the shear strength of joints was strongly depend on the welding current, type of filler and welding time. The joint strength decreases with an increasing level of current and weld nugget size. It was also found that welding time and welding currents are two important factors that brings good weldability of metals [2]. Thus, welding time, welding current and electrode force were chosen to be the varying parameters in this study. In order to identify parameter levels that provide the best performance, Taguchi method system was adopted. The optimum condition is selected so that the influence of uncontrollable factors can minimize variation to the system performance [3]. The chosen three parameters will be used further to evaluate the tensile shear strength of the welded specimen. Revised Manuscript Received on January 05, 2020 * Correspondence Author Nor Atirah Mat Yasin, Malaysia Rail Link Sdn Bhd, Kuala Lumpur, Wilayah Persekutuan, Malaysia. Anizahyati Alisibramulisi*, Faculty of Civil Engineering and Institute for Infrastructure Engineering and Sustainable Management (IIESM), Universiti Teknologi MARA (UiTM), Shah Alam, Selangor, Malaysia. Zuraidah Salleh, Fakulti Kejuruteraan Mekanikal, Universiti Teknologi MARA (UiTM), Shah Alam, Selangor, Malaysia. Farizah Adliza Ghazali, Fabrication & Joining Section, Universiti Kuala Lumpur Kampus Cawangan Malaysia France Institute (MFI), Bandar Baru Bangi, Selangor, Malaysia. Anuar Pawan, Jabatan Kerja Raya (JKR), Malaysia. The control of the welding parameters plays a major role in t he weld quality. [4]. Thus, a study on the optimization of these parameters by using Taguchi Method, is deemed necessary. II. METHODOLOGY A. Specimen preparation Low carbon steel is used as the type of specimen that is used in this study. This material is widely used to draw motorcycle parts, car bodies and other domestic applications [4]. The samples are prepared by cutting the material of the workpiece into correct dimensions of 1.2mm thickness, 45mm width, 105mm length and 35mm contacting overlap. The specimens were prepared for nine trials with different rate of welding time, welding current and electrode force, see Table I. Each trial has three to four numbers of specimens. The reason of why each trial has a different number of specimens is because, while cutting the specimens with the same dimension, there are three specimens that are left, so the remaining specimens were used in the fifth, eighth and ninth trial. The minimum number of specimens for each trial is three and for the trial that has four number of specimens, it will help to give a better result to obtain the optimum value of parameters. Table I: Number of specimens with the details for each parameter Trial Number of specimens Electrode force (kN) Welding current (kA) Welding time (cycles) 1 3 2.3 8 10 2 3 2.3 10 15 3 3 2.3 12 20 4 3 2.7 8 10 5 4 2.7 10 15 6 3 2.7 12 20 7 3 3.1 8 10 8 4 3.1 10 15 9 4 3.1 12 20 Material checking was conducted by using Arc Spark Optical Spectrometer machine with pure Argon 99.9% and its software of Spark Analyzer MX. Size of the sample needed for the checking of the composition of the specimen is 40mm x 40mm and the thickness of the specimen used for this checking must not be less than 1 mm. Three readings were taken from three different spots on the sample. From the test, the composition of the sample can be identified. The tested material’s chemical composition and mechanical properties are tabulated in Table II and Table III respectively. Optimization of Resistance Spot Welding (RSW) Parameters by using Taguchi Method Nor Atirah Mat Yasin, Anizahyati Alisibramulisi, Zuraidah Salleh, Farizah Adliza Ghazali , Anuar Pawan