This document discusses optimizing the process parameters for friction stir welding (FSW) of similar aluminum alloy H30 joints. Experiments were conducted using a Taguchi L9 orthogonal array with rotational speed, travel speed, and axial force as parameters. Tensile tests showed that maximum strength was achieved at 1600 RPM, 20 mm/min travel speed, and 6000N axial force. Analysis of variance identified axial force as the most significant parameter. The study aims to determine optimum parameters for high joint strength using Taguchi methodology.
Investigation of Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
Investigation of Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
Tungsten inert gas (TIG) welding in which the arc is formed between a pointed tungsten electrode and the work piece in an inert atmosphere of argon or helium but the activated TIG welding is that in which oxides of fluxes are used on work piece also called A-TIG. Current and voltage can have profound effect on the material in terms of strength and hardness. This research aims at the study of using conventional TIG (tungsten inert gas) and activated TIG welding process to investigate the effect of different levels of factors (current, voltage, gas flow rate, electrode diameter) on the mechanical properties of the mild steel using mixture of MgO and CaO flux. Mild steel specimens were used during the experimentation. The results of conventional TIG have been compared with the activated TIG welding. The method of design expert is used to carry out the experimentation. Moreover it is observed that there is decrease in hardness of weld but the quality of weld is increased as compared to conventional TIG welding.
URL: http://ijtir.hctl.org/A-Study-of-Mechanical-Properties-on-Tig-Welding-at-Different-Parameters-with-and-without-use-of-Flux.html
Study of Simulated Temperature of Butt Joint during Friction Stir Welding Of ...IJERA Editor
Friction stir welding (FSW) is one of the latest welding technology that utilizes a special tool for generation of frictional heat in the work piece by its rotation due to which joining occurs without melting of metal. For this reason friction stir welding lies under the category of solid state joining. A part from experimental work, there is large space to work on simulation of FSW by using simulation tools. In the present paper, simulation of friction stir welding of aluminium alloy AA-6061 is done by using HyperWeld module of Altair HyperWorks. The virtual experiment of friction stir welding is conducted for variable tool rotational speeds with constant travelling speed and study of simulation results of variation in temperature distribution along the weld line of butt joint is done. The results of simulation shows that the temperature is symmetrically distributed along the weld line. It is observed that the maximum temperature along the weld line increases with the increase in rotational speed. It is also observed that the temperature at advancing side is greater that retreating side.
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
Optimization of Preventive Maintenance Practice in Maritime Academy OronIJERA Editor
This research study investigates preventive maintenance management of diesel engine generators at the Nigerian Maritime Academy, Oron. An optimization methodology taking cognisance of equipment age was applied on failure data of diesel engine generators obtained from the institution’s maintenance data base to provide cost effective maintenance management / replacement programme for critical components of diesel engine generators. The analyzed results using Matlab provides a cost and reliability template which can be used to perform diesel generator maintenance management programme in the academy.
Implementationof Single Phasing, Over Voltage, Under Voltage, Protection of T...IJERA Editor
This paper tends to develop for protection for costly appliances which require three-phase AC supply for operation. Failure of any of the phases or sudden change in voltage makes the appliance prone to erratic functioning and may even lead to failure. Hence it is of paramount importance to monitor the availability of the three-phase supply and proper voltage supply and switch off the appliance in the event of failure of one or two phases or if required voltage level is not available. The power to the appliance should resume with the availability of all phases of the supply with proper voltage level. The main advantage of this protector circuit is that it protects three-phase appliances from failure of any phase as well as from fluctuation of voltage. The concept in future can be extended to developing a mechanism to send message to the authority via SMS by interfacing GSM modem. Details description of all types of faults is given below.
Modified design for Full Swing SERF and High Speed SERFIJERA Editor
In this chapter we have discussed the research work done on the basis of literature review and study. The
research methodology and the techniques to modify the present designs in order to achieve better performance
have been discussed with their merits and demerits. In this paper FS-SERF and HS- SERF full adder topologies
are presented. The analysis of Power, Delay, Power Delay Product (PDP) optimization characteristics of SERF
Adder is designed. In order to achieve optimal power savings at smaller geometry sizes, proposed a heuristic
approach known as FS-SERF and HS-SERF adder model.
Tungsten inert gas (TIG) welding in which the arc is formed between a pointed tungsten electrode and the work piece in an inert atmosphere of argon or helium but the activated TIG welding is that in which oxides of fluxes are used on work piece also called A-TIG. Current and voltage can have profound effect on the material in terms of strength and hardness. This research aims at the study of using conventional TIG (tungsten inert gas) and activated TIG welding process to investigate the effect of different levels of factors (current, voltage, gas flow rate, electrode diameter) on the mechanical properties of the mild steel using mixture of MgO and CaO flux. Mild steel specimens were used during the experimentation. The results of conventional TIG have been compared with the activated TIG welding. The method of design expert is used to carry out the experimentation. Moreover it is observed that there is decrease in hardness of weld but the quality of weld is increased as compared to conventional TIG welding.
URL: http://ijtir.hctl.org/A-Study-of-Mechanical-Properties-on-Tig-Welding-at-Different-Parameters-with-and-without-use-of-Flux.html
Study of Simulated Temperature of Butt Joint during Friction Stir Welding Of ...IJERA Editor
Friction stir welding (FSW) is one of the latest welding technology that utilizes a special tool for generation of frictional heat in the work piece by its rotation due to which joining occurs without melting of metal. For this reason friction stir welding lies under the category of solid state joining. A part from experimental work, there is large space to work on simulation of FSW by using simulation tools. In the present paper, simulation of friction stir welding of aluminium alloy AA-6061 is done by using HyperWeld module of Altair HyperWorks. The virtual experiment of friction stir welding is conducted for variable tool rotational speeds with constant travelling speed and study of simulation results of variation in temperature distribution along the weld line of butt joint is done. The results of simulation shows that the temperature is symmetrically distributed along the weld line. It is observed that the maximum temperature along the weld line increases with the increase in rotational speed. It is also observed that the temperature at advancing side is greater that retreating side.
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
Optimization of Preventive Maintenance Practice in Maritime Academy OronIJERA Editor
This research study investigates preventive maintenance management of diesel engine generators at the Nigerian Maritime Academy, Oron. An optimization methodology taking cognisance of equipment age was applied on failure data of diesel engine generators obtained from the institution’s maintenance data base to provide cost effective maintenance management / replacement programme for critical components of diesel engine generators. The analyzed results using Matlab provides a cost and reliability template which can be used to perform diesel generator maintenance management programme in the academy.
Implementationof Single Phasing, Over Voltage, Under Voltage, Protection of T...IJERA Editor
This paper tends to develop for protection for costly appliances which require three-phase AC supply for operation. Failure of any of the phases or sudden change in voltage makes the appliance prone to erratic functioning and may even lead to failure. Hence it is of paramount importance to monitor the availability of the three-phase supply and proper voltage supply and switch off the appliance in the event of failure of one or two phases or if required voltage level is not available. The power to the appliance should resume with the availability of all phases of the supply with proper voltage level. The main advantage of this protector circuit is that it protects three-phase appliances from failure of any phase as well as from fluctuation of voltage. The concept in future can be extended to developing a mechanism to send message to the authority via SMS by interfacing GSM modem. Details description of all types of faults is given below.
Modified design for Full Swing SERF and High Speed SERFIJERA Editor
In this chapter we have discussed the research work done on the basis of literature review and study. The
research methodology and the techniques to modify the present designs in order to achieve better performance
have been discussed with their merits and demerits. In this paper FS-SERF and HS- SERF full adder topologies
are presented. The analysis of Power, Delay, Power Delay Product (PDP) optimization characteristics of SERF
Adder is designed. In order to achieve optimal power savings at smaller geometry sizes, proposed a heuristic
approach known as FS-SERF and HS-SERF adder model.
Žaidimo taisyklės pasikeitė. Eilinis Jūsų klientas atliks produkto tyrimą ir jį įvertins interneto svetainėjė ir interneto tinkluose dar gerokai prieš tai, kol jūsų pardavėjai įsitrauks į pardavimo procesą. Kadangi šiuo metu vartotojai ieško ir perka internetu, B2B (V2V) pirkimas internetine transformavosi į interaktyvų procesą, kuri lemia klientas, o ne pardavėjas. Tiesą sakant, skambutis savo pardavėjui gali būti paskutinis žingsnis pirkėjo procese gerokai apribojant pačio pardavėjo įtaką ir patirtį, kuri iki šiol vesdavo pirkimo aptarimą. Tačiau iškylo avangardas inovatyvių įmonių, kurios išmoko, kaip išmoko analizuoti pirkėjų elgesį internete ir jo perspektyvas ankst\yvo pirkimo procese ir tokiu būdu įgyjo konkurencinį pranašumą bei laimėjo daugiau verslo sandorių. Šis pirkėjo internete elgesysv-interneto svetainių lankymai, parsisiuntimai, elektroninio pašto atsakymai, ir daugiau, yra tai, kas vadinama Skaitmenine kūno kalba. Skaitmeninės kūno kalbos įžvalgos gali atskleisti pirkėjų ketinimus pardavimų žmonėms.
Modified Sierpinski Gasket for Wi-Fi and WLAN ApplicationsIJERA Editor
The hasty growth of wireless technologies has drawn new demands for integrated components including antennas and antenna on chip is a new mantra in the area of antenna research. Various techniques have been suggested by researchers for the miniaturization of microstrip patch antennas with multiband characteristics. Numerous antennas for multiband operation have been studied and designed for communication and radar systems. One of the solutions for the multiband characteristics is the fractal antenna. The Fractal antennas are based on the concept of fractal geometries. They can be designed in a variety of shapes in order to obtain enhanced gain and bandwidth, dual band and circular polarization to even ultra-wideband operation. In this paper, the fractal antenna has been designed using the Arlon substrate with relative permittivity of 1.3 and a substrate of Sierpinski gasket shaped placed on it. Feed used is the line feed. The designed antenna is a low profile, small size and multiband antenna since it can be operated at different frequencies within the frequency range of (1.75 – 2.65) and (5.7 – 7.65) GHz. It includes the frequencies used for wireless WLAN application and used to receive and transmit a high-frequency signal.
Numerical Investigation of Jet Noise Prediction in Exhaust Nozzle by Passive ...IJERA Editor
The project mainly focuses on the reduction of jet noise emission in the exhaust nozzle of TURBOFAN ENGINES. Reduction of noise in the exhaust system is done by attaching chevrons with particular parameters in the nozzle exit. Numerical investigations have been carried out on chevron nozzles to assess the importance of chevron parameters such as the number of chevrons like (chevron count), chevron penetration and the mixing characteristics of co flow jet. Chevron count is the pertinent parameter for noise reduction at low nozzle pressure ratios, whereas at high nozzle pressure ratios, chevron penetration is crucial. The results illustrate that by careful selection of chevron parameters substantial noise reduction can be achieved. The sound pressure level (SPL) can be calculated from that we determined the noise level at nozzle exit section. After assessing the chevron parameters we are going to modify the chevron shapes in order to get maximum noise reduction along with very negligible thrust loss. Modification of chevron is based on aspect of increasing the mixing of cold jet and the hot jet in order to decrease the noise emission. ANSYS-Fluent is a commercial CFD code which will be used for performing the simulation and the simulation configuration contains three different velocities (100,150,200) with two different nozzle model(plain & chevron nozzle). The simulation results are evaluated to find out nozzle noise level in the engine exhaust system.
This project work is to investigate the compression efficiency of different configuration of Turbo-Prop Co-Rotor Blade System of Subsonic Axial Flow Compressor. By this method the highly compressed air can be passed over the intake of the engine to the compressor with high mass flow rate in change of low velocity and high pressure ratio. The length of the small rotor is varied in terms of large rotor length by 25,50 & 75% . Each will have three space configuration in terms of diameter of rotor and in the percentage of 5,10,15%. A total of 12 configurations will be simulated to arrive optimum blade configuration. The blades are made in the shape of an airfoil like wing of an aircraft. The engine rotates the propeller blades, which produce lift. This lift is called thrust and moves the aircraft forward. Blades are usually made of high lift airfoil which allows more rotation to generate high pressure for engine. ANSYS- Fluent is commercial software which is robust for most of the fluid dynamic problems and it is used in this project work to evaluate the different configurations of co-rotor propeller system to arrive the best.
Alex Shipillo - Director of Demand Generation, Influitive
Circulate Conference - April 11, 2016
W Hotel, San Francisco
Absract:
The role of marketing in B2B organizations is changing rapidly. Find out the secrets to building a strong foundation for data-driven marketing. Then, learn how you can expand beyond that baseline to drive better communication, transparency and ultimately, change across the revenue team. Alex will share how Influitive has built the marketing processes that have enabled 10x growth over the last two years.
http://alexshipillo.com/speaking
http://circulateconference.com
60-page communication audit utilizing quantitative and qualitative methods to assess the quality and effectiveness of Taco Bell’s website. Measurement tools & approaches include: KPI analysis, heuristic assessment, web metrics analysis, dashboard visuals, comparative benchmarking analysis and survey design and implementation.
Effect of Harvest of Air Relative Humidity on Water and Heat Transfer in Soil...IJERA Editor
In this work, the main objective is to analyze the effect of the harvest of air relative humidity on soil temperature, soil water storage and evaporation. An experiment work was conducted in order to evaluate the quantity of soil water adsorbed by harvesting of relative air humidity. This experimental work was conducted on hilly areas with various hypsographic and microclimatic conditions greatly affecting daily fluctuations of air humidity and soil characteristics. The metrological data needed by SISPAT model were obtained by using a Campbell Scientific equipments Station recorder on data loggers every half hour. A numerical model based on SiSPAT (Système d’Interaction Sol Plante Atmosphère) formulation is adopted. The general equations of the proposed model are based on heat and mass transfer in the soil, atmosphere and plant system. This study shows that Soil Water Adsorption (SWA) induce an increasing in the total evaporation and in soil water storage especially on the upper layers. The effect of Soil Water Adsorption on soil temperature appears for the first layers of soil and become absent in the profound zone because the vapour condensation phenomenon is very important at night for the first layers.
Experimental Study of an Atmospheric Pressure Dielectric Barrier Discharge an...IJERA Editor
A homogeneous dielectric barrier discharge (DBD) in argon was produced by applying high voltage A.C. source of potential difference (0-20) kV operating at a frequency of 10-30 kHz across two parallel plate electrodes with glass as dielectric barrier. The discharge was characterized by optical emission spectroscopy (OES) and electrical measurement. Four argon emission lines from the discharge were analyzed and the electron temperature was estimated by line intensity ratio method. The electron density in the discharge was estimated by power balance method. An investigation of the effect of inter-electrode distance on the electron density was made. The results showed that the electron temperature is less than 1 eV and the electron density is of the order of 1011cm-3 which varied with the inter electrode distance. Discharge was applied for surface modification of polyethylene terepthalate (PET). Modified surfaces were studied by contact angle measurement and FTIR spectroscopy.
Feature Extraction of Gesture Recognition Based on Image Analysis for Differe...IJERA Editor
Gesture recognition system received great attention in the recent few years because of its manifoldness applications and the ability to interact with machine efficiently through human computer interaction. Gesture is one of human body languages which are popularly used in our daily life. It is a communication system that consists of hand movements and facial expressions via communication by actions and sights. This research mainly focuses on the research of gesture extraction and finger segmentation in the gesture recognition. In this paper, we have used image analysis technologies to create an application by encoding in MATLAB program. We will use this application to segment and extract the finger from one specific gesture. This paper is aimed to give gesture recognition in different natural conditions like dark and glare condition, different distances condition and similar object condition then collect the results to calculate the successful extraction rate.
A Novel Control Method for Unified Power Quality Conditioner Using Nine-Switc...IJERA Editor
A nine-switch power converter having two sets of out-put terminals was recently proposed in place of the traditional back-to-back power converter that uses 12 switches in total. The nine-switch converter has already been proven to have certain advantages, in addition to its component saving topological feature. Despite these advantages, the nine-switch converter has so far found limited applications due to its many perceived performance tradeoffs like requiring an oversized dc-link capacitor, limited amplitude sharing, and constrained phase shift between its two sets of output terminals. Instead of accepting these tradeoffs as limitations, a nine-switch power conditioner is proposed here that virtually “converts” most of these topological short comings into interesting performance advantages. Aiming further to reduce its switching losses, an appropriate discontinuous modulation scheme is proposed and studied here in detail to doubly ensure that maxi-mal reduction of commutations is achieved. With an appropriately designed control scheme then incorporated, the nine-switch converter is shown to favorably raise the overall power quality in experiment, hence justifying its role as a power conditioner at a reduced semiconductor cost.
Research on Privacy Protection in Big Data EnvironmentIJERA Editor
Now big data has become a hot topic in academia and industry, it is affecting the mode of thinking and working, daily life. But there are many security risks in data collection, storage and use. Privacy leakage caused serious problems to the user, false data will lead to error results of big data analysis. This paper first introduces the security problems faced by big data,analyzes the causes of privacy problems,discussesthe principle to solve the problem. Finally,discusses technical means for privacy protection.
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This paper is a review of research work in the last decade on friction stir welding. In many industrial applications steel is readily replaced by non-ferrous alloys like aluminum alloys. Aluminum alloys having good mechanical properties as equated structural steel and low weight that allows a significant reduction in weight. But the welding of aluminum alloys by regular processes can causes serious problems. The difficulties are like loss of alloying elements and presence of separation and porosities in the weld joint. Friction stir welding (FSW) is a solid state welding process, which removes all these problems of solidification related with the conventional fusion welding processes. In this research work an attempt has been made to develop an the relationship between FSW variables (tool rotation and tilt angle) and tensile strength and yield strength of number of pass friction stir welded aluminium alloy AA 6082 butt joints. Taguchi method is used for analysing the problem in which several independent variables influence the response. A three-parameter -three-level central composite design was used to determine the optimal factors of friction stir welding process for aluminium alloy.
Friction stir welding of aluminium 5086 alloyseSAT Journals
Abstract Friction Stir welding (FSW) is a solid state attachment method used for welding of metals of same and different metals. This process of friction stir welding (FSW) is widely using for the reason it can produces sound welds and doesn't have common issues like solidification and liquefaction cracking connected to the fusion techniques. The Friction stir welding of Al 5086 alloys had been commercialized and up to date interest is targeted on change of integrity with different metals. Thus on commercialize this method, analysis studies are required to characterize. particularly, FSW has impressed researchers to aim modification of integrity different metals like aluminum 5086 that differ in properties and sound welds with none or restricted inter metallic bonding of components has been done. In this paper we have to make a research on the current analysis state of FSW between aluminum 5086 with attention on the resulting welding and tensile strength, microstructure, elongation and the tools are used to produce the welds and also an insight into future analysis during this process of study the project of friction welding. By this process in our project we got an idea of going to maintain the rotational speed (rpm) 450 to 1400 and also by changing welding rpm (speed). This friction stir welding is used in nasa for joining of two totally different or same types of materials. Keywords: Friction stir welding, Tool, Welding parameters, and Mechanical properties etc…
The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company ‒ Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ‒ Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.
Friction Stir Welding of Similar Metals by Taguchi Optimization Technique -A ...IJAEMSJORNAL
In order to meet the global competition and the survival of products in the market a new way of thinking is necessary to change and improve the existing technology and to develop products at economical price.This paper discusses use taguchi experiment design technique for maximizing tensile strength of friction stir welding AA6061 and AA6061. In friction stir welding, the joints are formed in the solid state by utilizing the heat generated by friction. The objectives of this study are obtaining friction weld element of aluminium 6061 to aluminium 6061 and optimising the friction stir welding parameters in order to establish the weld quality. Effect of tensile strength of friction stir welding process parameter (Rotational speed, travel speed, axial force and tilt angle) is evaluated and optimum welding condition for maximum tensile strength is determined.
FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEWIAEME Publication
This welding is a novel process used to join metallic alloys. Friction stir welding is in vogue in aerospace, automotive and other industrial establishments for connecting alloys like aluminum, magnesium and copper. Rotational speed, welding speed and the angle of attack are important in the process of FSW. They analyze the weld quality. FSW produces stronger weld joint then the original material in selected parameters. FSW is a solid-state process, where metal is not melted uses a cylindrical shouldered tool with a profiled pin rotated and gradually plunged into the weld joint between two metal parts of plate or sheet that are to be welded together.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
Similar to Effect of Process Parameters of Friction Stir Welded Joint for Similar Aluminium Alloys H30 (20)
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Effect of Process Parameters of Friction Stir Welded Joint for Similar Aluminium Alloys H30
1. VANITA S. THETE Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 5, ( Part -6) May 2015, pp.10-17
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Effect of Process Parameters of Friction Stir Welded Joint for
Similar Aluminium Alloys H30
Vanita S. Thete1
, Vijay L. Kadlag
Mechanical Engineering Department, S.V.I.T. COE, Nashik, (Maharashtra), India
Abstract
In this paper the effect of process parameters of friction stir welded joint for similar aluminium alloys H30 was
studied. Taper cylindrical with three flutes all made of High speed steel was used for the friction stir welding
(FSW) aluminium alloy H30 and the tensile test of the welded joint were tested by universal testing method.
The optimization done using detailed mathematical model is simulated by Minitab17. In this investigation, an
effective approach based on Taguchi method, has been developed to determine the optimum conditions leading
to higher tensile strength. Experiments were conducted on varying rotational speed, transverse speed, and axial
force using L9 orthogonal array of Taguchi method. The present study aims at optimizing process parameters to
achieve high tensile strength.
Key words: Friction stir welding (FSW) Tool, CNC milling machine, Aluminium alloy H30, Minitab17,
Tensile test, taper cylindrical tool.
I. INTRODUCTION
Friction stir welding is a version of pressure
welding processes. It was recently developed in
England by welding institute (TWI) in 1991.It can
be created high quality weld by using CNC milling
machine because using same movement conditions
but tool is different. Friction stir welding is
extensively used for Al, Mg .Cu, Ti, for work pieces
that could not welded by conventional types of
welding and different applications because of
economical and quality consideration [1]. This
technique has been extended to similar as well as
dissimilar welding of the above mentioned alloys
and also to the welding of steels [2]. FSW done on
CNC milling machine for small work pieces to
professional single purpose robotic machine in
orbital FSW in steel pipes welding in oil industries
[3]. The schematic of friction stir process shown in
Figure 1.
Friction Stir Welding has advantages over the
conventional welding techniques some of which
include very low distortion, no fumes, porosity or
spatter, no consumables (no filler wire), no special
surface treatment and no shielding gas requirements.
so it has been widely used in the aerospace,
shipbuilding, automobile industries and in many
applications.
In FSW, there have been lots of efforts to understand
the effect of process parameter on flow behavior,
microstructure formation and hence mechanical
properties of FSW joints. To study the effect of FWS
process parameters, most workers follow the
traditional experimental techniques, i.e. varying one
parameter at a time and keeping others constant. In
last experiment we were taken three parameters like
rotational speed, travel speed and constant welding
depth. Now in recent paper we were changed the
constant parameter that means we taken axial force
instead of welding depth.
Fig. 1: Schematic of Friction Stir Welding.
Taguchi method is a power full method which
can improve the performance of the product is that
the optimization of process parameters of similar
alloy H30-H30 using Taguchi method has not
repeated yet. Taguchi method is used to analyze the
effect of process parameter (i.e. rotational speed,
transverse speed, and axial force) for optimizing
tensile strength of FS Welds of similar aluminium
alloys H30-H30.
II. LITERATURE REVIEW:
In Omid Ali Zargar project he was using three
type of tools, straight cylindrical, taper cylindrical
and triangular tool all made of High speed steel
(Wc-Co) for the friction stir welding (FSW)
aluminum alloy H20 –H20 and test the mechanical
RESEARCH ARTICLE OPEN ACCESS
2. VANITA S. THETE Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 5, ( Part -6) May 2015, pp.10-17
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properties of the welded joint by tensile test and
vicker hardness test[1].
M. Pouranvari studied the effect of transient
liquid phase (TLP) bonding condition on the
mechanical properties of GTD-111 nickel base
superalloy investigated. [2].
N. T. Kumbhar and K. Bhanumurthy was
carefully chosen the tool geometry and fabricated to
have a nearly flat welded interface. Important
process parameters that control the quality of the
weld are axial force, rotation speed (rpm), traverse
speed (mm/min) and tool tilt angle and these process
parameters were optimized to obtain defect free
welded joints. It is observed that, during the friction
stir welding, extensive deformation is experienced at
the nugget zone and the evolved microstructure
strongly affects the mechanical properties of the
joint [3]. In this present study FSW of AZ31B are
used to improve the process parameters [4].
III. TAGUCHI METHOD
Optimization of process parameter is the
important in the Taguchi method to achieving high
quality without increasing cost. It can improve
quality and the optimal process parameters obtained
from the Taguchi method and other
noise factors. Taguchi method is
experimental design easy to apply for
many engineering applications. Taguchi method can
be used to quickly narrow the scope of a research
project or to identify problems in a manufacturing
process.
When the number of the process parameters
increases, a large number of experiments have to be
carried out. To solve, the Taguchi method uses a
special design of orthogonal array to study the entire
process parameter with only a small number of
experiments.
3.1 FSW Process Parameters:
Process parameters plays important role in deciding
the weld quality. The process parameter was selected
shown in table.
Table1. Process Parameters with corresponding
levels
Sr.
No
Process
Parameters
Range Level
1
Level
2
Level
3
1
Rotational
speed
1200-
1600
rpm
1200 1400 1600
2
Travel
speed
10-30
mm/min
10 20 30
3
Axial Force 2000-
6000N
2000 4000 6000
IV. MATERIALS AND METHODOLOGY
4.1 Aluminium alloy H30:
The work piece materials selected for this
investigation were AA6082-T6 and 6082-T6
aluminium alloys sheets of 6.5 mm thickness having
chemical composition and shown in the Table 1. In
the present study, size of sheets is 100mm x 70mm
of AA6082-T6 and AA6082-T6 were cut for
welding by FSW.
Fig.2 Work piece Dimensions
Table 2 .Chemical Composition of H30:
1. Alloy Designations:
Aluminium alloy 6082 also corresponds to the
following standard designations and specifications
but may not be a direct equivalent:
AA6082
HE30
DIN 3.2315
EN AW-6082
ISO: Al Si1MgMn
A96082
4.2 Selection of Tool:
The friction stir welding tool consists of a pin, or
probe, and a shoulder. Contact between pin and
workpiece creates frictional and heating and softens
the workpiece material contacting the shoulder to the
workpiece increases the workpiece heating, expands
the zone of softened material.
1. Material:
Friction stir welding is a thermo mechanical
deformation process where material of base plate
deforms due to the temperature created by shoulder.
Friction stir weld requires the proper tool material
selection for the desired application.
2. HSS:
Taper Cylindrical tool with three flutes used in
present study which was made of high-speed tool
steel. This is most commonly used material and has
some good mechanical properties like easy
Element Mg Si Fe Cu Cr Zn Ti Mn Al
% 0.69 0.60 0.30 0.10 Nil 0.06 Nil 0.38 Balance
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availability and machinability, thermal fatigue
resistance, wear resistance, especially for aluminium
and copper.
4.3. Design of tool:
Tool was made in two different parts due to the
length of pin, one is shoulder for holding purpose
and another is tip or pin which is penetrated in base
material.
A. Taper cylindrical tool with three flutes: the
length of pin is 5mm and its shape is paper
cylindrical. Also three flutes are provided on pin for
wear and also provided the circular shape on the
shoulder as shown below. All the dimensions of tool
is also shown in fig.3
Fig. 3 Friction stir welding taper cylindrical tool
with three flutes
Fig.4 Taper cylindrical tool with dimensions:
4.4 Friction Stir Welding Procedure:
Nine experiments parameters have been performed
on Al-6082 plates by L9 orthogonal array. The three
factors used in this experiment are the rotating
speed, axial force and travel speed. The factors and
the levels of the process parameters are presented in
Table.3 and these parameters are taken based on the
previous trials to weld the FSW of aluminium‟s. The
experiments are performed on a vertical milling
machine.
Table.3 Experimental layout of L9 Orthogonal array
Experiment Rotational
speed
Travel
speed
Axial
Force
1 1200 10 1200
2 1200 20 1400
3 1200 30 1600
4 1400 10 1400
5 1400 20 1600
6 1400 30 1200
7 1600 10 1600
8 1600 20 1200
9 1600 30 1400
Fig.5 shows Tool on VMC
V. WELD TESTING PROCEDURE:
Tensile test performed on universal testing
machine after friction stir welding. Testing
performed in temperature between 10 to 30°C if A is
the cross sectional area and F is the maximum force
and tensile strength calculated by:
Tensile strength=F/A
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Fig.6 Process Setup for Tensile Test
Fig.7 Tensile specimen before failure
Fig.8 Tensile specimen after failure
Table.4 The input parameter of orthogonal array and
the output characteristics
Sr.
No.
Rotational
Speed
(RS)
RPM
Travel
Speed
(TS)
mm/Min
Axial
Force
(AF)
N
Tensile
strength
(Mpa)
1 1200 10 2000 69
2 1200 20 4000 55
3 1200 30 6000 66
4 1400 10 4000 32
5 1400 20 6000 80
6 1400 30 2000 32
7 1600 10 6000 77
8 1600 20 2000 69
9 1600 30 4000 59
VI. RESULT DISCUSSION:
6.1 Friction Stir Welded Joint Results:
We weld the mention dimension of aluminium alloy
H30-H30 with the mentioned process parameter was
successfully done on CNC milling machine with
taper cylindrical tool (with three flutes) & then
perform tensile strength test to the welded joints
compare the results and make conclusion.
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ISSN : 2248-9622, Vol. 5, Issue 5, ( Part -6) May 2015, pp.10-17
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Fig.9 Al alloy H-30 before and after welding
6.2. S/N Ratio Analysis:
The term „Signal‟ represents the desirable value
(mean) for the output characteristics and the term
„noise‟ represents the undesirable value for the
output characteristic. The S/N ratio are uses to
measure the quality characteristic deviating from the
desired value in Taguchi method. The S/N ratios
available depending on type of characteristic: lower
is better (LB), nominal is best (NB), larger is better
(LB). Larger is better S/N ratio was used here.
Larger the better characteristic
S/N= -10 log10 (MSD)
MSD = (1/Y12
+ 1/Y22
+ 1/Y32
+................)/n
Where Y1, Y2, Y3 are the responses and n is the
number of trial and m is the target value of result.
The highest S/N ratio was the optimum level for
responses measured.
Fig.10 Tool after welding Fig.11 work piece after
welding
Table 5: S/N ratio of tensile strength of FS Welds
Fig.12 Mean and S/N ratio of tensile strength of FS
Welds
Higher value of S/N ratio was selected for the input
parameters. The optimum input parameter for
friction stir welding joints are rotational speed 1600
(level 3), transverse speed 20mm/min and constant
welding depth 5mm. the S/N ratio was directly
found on MINITAB 17.
6.3 Taguchi Design :
Taguchi Orthogonal Array Design
L9 (3^3)
Factors: 3
Runs: 9
Columns of L9 (3^4) Array
1 2 3
Taguchi Analysis: tensile strength versus
rotational speed, transverse speed
Sr.
No.
Rotational
Speed
(RS)
RPM
Travel
Speed
(TS)
mm/Mi
n
Axial
Force
(WF)
N
Tensile
Strength
(UTS)
Mpa
S/N
Ratio
1 1200 10 2000 69 36.7770
2 1200 20 4000 55 34.8073
3 1200 30 6000 66 36.3909
4 1400 10 4000 32 30.1030
5 1400 20 6000 80 38.0618
6 1400 30 2000 32 30.1030
7 1600 10 6000 77 37.7298
8 1600 20 2000 69 36.7770
9 1600 30 4000 59 35.4170
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ISSN : 2248-9622, Vol. 5, Issue 5, ( Part -6) May 2015, pp.10-17
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Larger is better
Table 6 Response Table for Signal to Noise Ratios
Level RS TS AF
1 35.99 34.87 34.55
2 32.76 36.55 33.44
3 36.64 33.97 3739
Delta 3.89 2.58 3.95
Rank 2 3 1
Table 7 Response Table for Means
Level RS TS AF
1 63.33 59.33 56.67
2 48.00 68.00 48.67
3 68.33 52.33 74.33
Delta 20.33 15.67 25.67
Rank 2 3 1
Fig.13 Main Effect Plot For SN Ratio
Fig.14 Main Effect Plot For Mean
6.4. Analysis Of Variance (ANOVA)
Analysis of variance (ANOVA) test was performed
to identify the average performance of process
parameters that are statistically significant. The
ANOVA test is to investigate the significance of the
process parameters which affect the tensile strength
of FSW joints. The ANOVA results for tensile
strength of means and S/N ratio are given in Table 4.
In addition, larger F-value indicates the variation of
process parameters makes big change on
performance. The Smaller p-value, greater the
significance of the process parameter.
Table 8 Analysis of Variance for SN ratios
Source D
F
Seq
SS
Adj
SS
Adj
MS
F P
Rotation
al Speed
2 25.9
9
25.9
9
12.99
4
2.1
8
0.31
4
Transver
se Speed
2 10.2
8
10.2
8
5.138 0.8
6
0.53
7
Axial
Force
2 24.9
2
24.9
2
12.46
2
2.0
9
0.32
3
Error 4 11.9
1
11.9
1
5.955
Total 8 73.1
0
7. VANITA S. THETE Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 5, ( Part -6) May 2015, pp.10-17
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Table 9 Analysis of Variance for Means
Source DF Seq SS Adj
SS
Adj
MS
F P
Rotational
speed
2 673.6 673.6 336.8 1.67 0.37
4
Transverse
speed
2 369.6 369.6 184.8 0.92 0.52
2
Axial
Force
2 1034.9 1034.
9
517.4 2.57 0.28
0
Error 4 402.9 402.9 201.4
Total 8 2480.9
Table.10 Optimized result obtained from ANOVA –
Minitab
Rotational
Speed
in Rpm
Transverse
Speed
in mm/Min
Axial
Force
in N
Taguchi
Method
1600 20 6000
6.5 Regression Analysis:
Regression Equation
UTS = 31.7 + 0.0125 RS + 0.00442 AF - 0.350 TS
Where, UTS is the response in terms of ultimate
tensile strength and RS, TS is input parameters.
If we put optimum parameters which are drawn by
ANOVA in equation it will give optimum value of
quality characteristics which will maximum tensile
strength.
UTS = 31.7 + 0.0125* RS + 0.00442* AF -
0.350* TS
UTS = 31.7 + 0.0125 *RS + 0.00442 *AF -
0.350 *TS
UTS= 71.22 Mpa predicted by regression equation.
6.6 Confirmation Testing:
Larger the better characteristic
S/N= -10 log10 (MSD)
MSD = (1/Y12
+ 1/Y22
+ 1/Y32
+................)/n
Where Y1, Y2, Y3 are the responses and n is the
number of tests in a trial and m is the target value of
result. The level of a factor with the highest S/N
ratio was the optimum level for responses measured.
In order to test the predicted result, confirmation
experiment has been conducted by running three
trials at the optimal setting of the process parameters
determine from the analysis i.e. A3, B2, C3. Error
between experimental valued and predicted valued
by regression equation is 1.44 which is less than 5%‟
Table 11Result of Average UTS & S/N Ratio
Trial UTS (Mpa) S/N
Ratio
1 2 3 Experimental predicted %
Error
1 69 77 72 72.67 71.22 1.44 37.227
VII. CONCLUSION:
The following conclusions have been derived by
applying TAGUCHI METHOD on the experimental
investigations of AA 6082-T6 and AA 6082-T6
alloys by FSW.
1. The cylindrical tool with a tapered pin
diameter have efficient stirring of the metal
and efficient filling of the material in the
gap formed during the welding process.
Friction stir welding can apply successfully
for aluminum alloy H30-H30 by CNC
milling machine.
2. Friction stir welding window was
developed to decide the range of tool
rotational speed, travel speed and axial
force.
3. The tensile strength increases with increase
in the tool rotational speed and reaches
maximum .The optimum value of process
parameters such as rotational speed,
traverse speed and axial force are found to
be 1600rpm (level3), 20 mm/min (level 2)
and 6000 N (level 3) respectively.
4. The Analysis of Variance for the tensile
result concludes that the Rotational Speed
is the most significant parameter with a
percentage of 35.55 %, followed by the
travel feed of 14.06 % and axial force
34.09%.
5. Friction stir welding is apply successfully
for aluminum alloy H30-H30 by CNC
milling machine.
6. The optimum value of process parameters
such as rotational speed, traverse speed and
welding depth are found to be 1400rpm
(level 2), 20 mm/min (level 2) and 5mm
(constant) respectively.
REFERENCES:
[1]. Omid A. Zarga, Friction Stir Welded Joint
Aluminum Alloy H20-H20 with Different
Type of Tools Mechanical Properties World
Academy of Science, Engineering and
Technology International Journal of
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