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Simulation of the Effects of Input Parameters on Weld Quality in Laser Transmission Welding (LTW) Using a Combined Response Surface Methodology (RSM)-Finite Element Method (FEM) Approach
N. Kumar and A. Bandyopadhyay

In this research contour laser transmission welding (LTW) of thermoplastics is systematically studied through process modelling, finite element method (FEM) and response surface methodology (RSM) combined approach. Effect of process parameters on temperature field and weld bead dimension have been studied. The thermal field simulated by solving a three-dimensional (3-D) transient heat diffusion equation with temperature dependent material properties using the COMSOL multi-physics. MINITAB 16 software has been used for experimental design. RSM is applied for developing mathematical models based on simulation results. The interactions of process parameters on the responses are studied using the developed response surface models. It is found that responses like, weld width, depth of penetration in absorbent part and maximum temperature at weld interface have been decreased with increasing value of scanning speed. According to analysis-of-variance (ANOVA) the laser power and spot diameter is the significant factors on the maximum temperature at weld interface.

Keywords: Diode laser, laser transmission welding (LTW), finite element method (FEM), response surface methodology (RSM), analysis-of-variance (ANOVA), COMSOL multi-physics, central composite face-cantered design

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