• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.4
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• pp.89-96
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• 2002

This paper aims to develop an intelligent model for predicting top-bead width for the robotic GMA(Gas Metal Arc) welding process using BP(Back-propagation) neural network and multiple regression analysis. Firstly, based on experimental data, the basic factors affecting top-bead width are identified. Then BP neural network model and multiple regression models of top-bead width are established. The modeling methods and procedure are explained. The developed models are then verified by data obtained from the additional experiment and the predictive behaviors of the two kind of models are compared and analysed. Finally the modeling methods, predictive behaviors md the advantages of each models are discussed.

• Proceedings of the KWS Conference
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• 2006.10a
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• pp.271-273
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• 2006

This paper focuses on the developed empirical models for the prediction on top-bead width in GMA(Gas Metal Arc) welding process. Three empirical models have been developed: linear, curvilinear and an intelligent model. Regression analysis was employed fur optimization of the coefficients of linear and curvilinear model, while Genetic Algorithm(GA) was utilized to estimate the coefficients of intelligent model. Not only the fitting of these models were checked, but also the prediction on top-bead width was carried out. ANOVA analysis and contour plots were respectively employed to represent main and interaction effects between process parameters on top-bead width.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1845-1848
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• 2005

The automatic $CO_2$ welding is a manufacturing process to produce high quality joints for metal and it could provide a capability of full automation to enhance productivity. Despite the widespread use in the various manufacturing industries, the full automation of the robotic $CO_2$ welding has not yet been achieved partly because the mathematical model for the process parameters of a given welding task is not fully understood and quantified. Several mathematical models to control welding quality, productivity, microstructure and weld properties in arc welding processes have been studied. However, it is not an easy task to apply them to the various practical situations because the relationship between the process parameters and the bead geometry is non-linear and also they are usually dependent on the specific experimental results. Practically, it is difficult, but important to know how to establish a mathematical model that can predict the result of the actual welding process and how to select the optimum welding condition under a certain constraint. In this research, an attempt has been made to develop an intelligent algorithm to predict the weld geometry (top-bead width, top-bead height, back-bead width and back-bead height) as a function of key process parameters in the robotic $CO_2$welding. A sensitivity analysis has been conducted and compared the relative impact of three process parameters on bead geometry in order to verify the measurement errors on the values of the uncertainty in estimated parameters.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.301-306
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• 2002

This paper presents the use of the neural network technology to establish a mathematical model for predicting bead geometry (top-bead width, top-bead height, back-bead width and back-bead height) for multi-pass welding, and understand relationships between process parameters and bead geometry for robotic GMA welding process. Using a series of robotic arc welding, additional multi-pass butt welds were carried out in order to verify the performance of the developed neural network model. The results show that not only the proposed model can predict the bead geometry with reasonable accuracy and guarantee the uniform weld quality, but also the neural network model could be better than the linear and curvilin ear equations developed from Lee [8].

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.170-174
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• 2004

Despite the widespread use in the various manufacturing industries, the full automation of the robotic CO$_2$ welding has not yet been achieved partly because the mathematical model for the process parameters of a given welding task is not fully understood and quantified. Several mathematical models to control welding quality, productivity, microstructure and weld properties in arc welding processes have been studied. However, it is not an easy task to apply them to the various practical situations because the relationship between the process parameters and the bead geometry is non-linear and also they are usually dependent on the specific experimental results. Practically, it is difficult, but important to know how to establish a mathematical model that can predict the result of the actual welding process and how to select the optimum welding condition under a certain constraint. In this paper, an attempt has been made to develop an Radial basis function network model to predict the weld top-bead width as a function of key process parameters in the robotic CO$_2$ welding. and to compare the developed model and a simple neural network model using two different training algorithms in order to verify performance. of the developed model.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.1
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• pp.30-35
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• 2016

Tandem arc welding is a guarantor for high efficiency and cost saving since the quantity of wire which is deposited in the welding is approximated 30% greater that in conventional welding. The welding process is now being successfully applied in many industries. However, in the case of tandem arc welding, good quality and high productivity should depend on the welding parameters. Therefore, an intelligent algorithms for the automatic tandem arc welding process has been necessarily required. In this study, a predictive model based on the neural network by using the data acquired during tandem gas metal arc (GMA) welding process has been developed. To verify the reliability of the developed predictive model, a mutual comparison with the surface of the top-bead width obtained from actual experiments has been analyzed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.596-599
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• 2004

The robotic $CO_2$ welding is a manufacturing process to produce high quality joints for metal and it could provide a capability of full automation to enhance productivity. Despite the widespread use in the various manufacturing industries, the full automation of the robotic $CO_2$ welding has not yet been achieved partly because the mathematical model for the process parameters of a given welding task is not fully understood and quantified. Several mathematical models to control welding quality, productivity, microstructure and weld properties in arc welding processes have been studied. However, it is not an easy task to apply them to the various practical situations because the relationship between the process parameters and the bead geometry is non-linear and also they are usually dependent on the specific experimental results. Practically, it is difficult, but important to know how to establish a mathematical model that can predict the result of the actual welding process and how to select the optimum welding condition under a certain constraint. In this research, an attempt has been made to develop an intelligent algorithm to predict the weld geometry (top-bead width, top-bead height, back-bead width and back-bead height) as a function of key process parameters in the robotic $CO_2$welding. To achieve this above objective, Taguchi method was employed using five different process parameters (tip gap, gas flow rate, welding speed, arc current, welding voltage) as a guide for optimization of process parameters.

• 제어로봇시스템학회:학술대회논문집
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• 1996.10b
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• pp.1404-1407
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• 1996

A quality monitoring system in butt welding process is proposed to estimate weld pool sizes. The geometrical parameters of the weld pool such as the top bead width and the penetration depth plus half back width are utilized to prove the integrity of the weld quality. The monitoring variables used are the surface temperatures measured at three points on the top surface of the weldment. The temperature profile is assumed that it has a gaussian distribution in vertical direction of torch movement and verify this assumption through temperature analysis. A neural network estimator is designed to estimate weld pool size from temperature informations. The experimental results show that the proposed neural network estimator which used gaussian distribution as temperature information can estimate the weld pool sizes accurately than used three point temperatures as temperature information. Considering the change of gap size in butt welding, the experiment were performed on various gap size.

• Journal of Welding and Joining
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• v.12 no.1
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• pp.59-72
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• 1994

This paper presents an on-line quality monitoring and control method to obtain a uniform weld quality in gas metal arc welding (GMAW) processes. The geometrical parameters of the weld pool such as the top bead width and the penetration depth plus half back width are utilized to assess the integrity of the weld quality. Since a good quality weld is characterized by a relatively high depth-to-width ratio in its dimensions, the second geometrical parameter is regulated to a desired one. The monitoring variables are the surface temperatures measured at various points on the top surface of the weldment which are strongly related to the formation of the weld pool The relationship between the measured temperatures and the weld pool size is implemented on the multilayer perceptrons which are powerful for realization of complex mapping characteristics through training by samples. For on-line quality monitoring and control, it is prerequisite to estimate the weld pool sizes in the region of transient states. For this purpose, the time history of the surface temperatures is used as the input to the neural estimator. The control purpose is to obtain a uniform weld quality. In this research, the weld pool size is directly regulated to a desired one. The proposed controller is composed of a neural pool size estimator, a neural feedforward controller and a conventional feedback controller. The pool size estimator predicts the weld pool size under growing. The feedforward controller compensates for the nonlinear characteristics of the welding process. A series of simulation studies shows that the proposed control method improves the overall system response in the presence of changes in torch travel speed during GMA welding and guarantees the uniform weld quality.

• Interaction and multiscale mechanics
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• v.6 no.2
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• pp.157-172
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• 2013

This paper presented an investigation of macromolecular suspension in a grooved channel by using the dissipative particle dynamics (DPD) with finitely extensible non-linear elastic (FENE) bead spring chains model. Before studying the movement and evolution of macromolecules, the DPD method was first validated by modeling the simple fluid flow in the grooved channel. For both simple fluid flow and macromolecular suspension, the flow fields were analyzed in detail. It is found that the structure of the grooved channel with sudden contraction and expansion strongly affects the velocity distribution. As the width of the channel reduces, the horizontal velocity increases simultaneously. Vortices can also be found at the top and bottom corners behind the contraction section. For macromolecular suspension, the macromolecular chains influence velocity and density distribution rather than the temperature and pressure. Macromolecules tend to drag simple fluid particles, reducing the velocity with density and velocity fluctuations. Particle trajectories and evolution of macromolecular conformation were investigated. The structure of the grooved channel with sudden contraction and expansion significantly influence the evolution of macromolecular conformation, while macromolecules display adaptivity to adjust their own conformation and angle to suit the structure so as to pass the channel smoothly.