The document summarizes a thesis submitted for a Master's degree in Production Engineering. It investigates the friction drilling process through finite element modeling, experimental testing, and analysis of results. The study aims to introduce friction drilling to Egyptian industries by developing low-cost tooling, optimizing process parameters, and evaluating their effects on hole quality, material microstructure, and hardness. Key aspects examined include tool design, experimental setup and methodology, finite element modeling, microstructural analysis, and the influence of rotational speed, feed rate and workpiece material on forces, torque and hole quality. The results provide insight into friction drilling of aluminum, steel and stainless steel and validation of the finite element model.
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. Friction Stir Welding(FSW) process is an emerging solid state joining process in which
the material that is being welded does not melt and recast when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
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.
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
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. Friction Stir Welding(FSW) process is an emerging solid state joining process in which
the material that is being welded does not melt and recast when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
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.
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
Effect of welding parameters and tool shape on properties of friction stir we...IJERA Editor
Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. It has many benefits when applied to welding of aluminum alloys. FSW process parameters such as welding speed, rotational speed and tool geometry play vital roles in the weld quality. The aim of this research is to investigate the effects of different welding speeds, rotational speeds and tool pin profile on the weld quality of a AA6061 aluminum alloy. A friction stir welding tool consists of rotating shoulder and pin that heats the working piece by friction and moves a softened alloy around it to form a joint. In this research work the effect of the tool shape and welding parameters (rotating speed and welding speed) on the mechanical properties of an aluminium plates will be investigated experimentally. The induced heat during the welding process played the main role in the mechanical and appearance of the joints, which is related to the welding parameters.
Optimization of friction stir welding parameters for joining aluminum alloy 6...eSAT Journals
Abstract This investigation represents the effects of parameters of friction stir welding on tensile strength and hardness during welding of Aluminium Alloy 6105. A fabricated FSWM set up was used for welding. A high carbon steel tool having 18 mm shoulder diameter and 5.5 mm pin diameter has been used. It was noted that for the friction stir welding of aluminium alloy 6105, maximum tensile strength is 0.0912 KN/mm2, which is obtain at 1250 rpm tool rotation speed, 25 mm/min welding speed and 00 tilt angle. It was also noted that the maximum vicker hardness is 65.7 which is obtain at 1550 rpm rotational speed, 35 mm/min welding speed and 0.50 tilt angle. Keywords: Friction stir welding, Aluminium alloy 6105, tensile strength, hardness, Taguchi L9 orthogonal array
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.
ANALYSIS OF TOOL USED FOR FRICTION STIR SPOT WELDING BY EXPLICIT MESHING SCH...vivatechijri
FSSW is an advanced and popular solid-state material welding method, which has achieved a
different variety of popularity in service in industries and automotive. FSSW method (technique) is used for joining
similar or dissimilar materials like aluminium, titanium, magnesium and copper alloys etc. This paper presents
finite element modeling of friction stir spot welding (FSSW) process using Abaqus/Explicit as a finite element
solver. Three-dimensional coupled thermal-stress model was used to calculate thermo-mechanical response of
FSSW process. The various factors such as rotational speed, transverse speed and profile of the tool plays a very
significant role in the joining quality of material using FSSW.
The main target of this analysis is to observe the variation of tool profile and welding quality of Ti 6Al 4V alloy
as the tool speed varies. Two Ti 6Al 4V were lapped and provided with support to the bottom of the plate known
as a back anvil to constrain the motion. This is where we analyzed the material flow due to friction of heat
generation in the weld zone. Ti 6Al 4V is one of the most commonly used materials and its applications, where
low density and excellent corrosion is applied in a wide range of resistance, are necessary in industries such as
aerospace industry and biomechanical, marine, chemical industries, gas turbine, etc.
Extrusion can be defined as the process of subjecting a material to compression so that it is forced to
flow through an opening of a die and takes the shape of the hole. Multi-hole extrusion is the process of
extruding the products through a die having more than one hole. Multi-hole extrusion increases the production
rate and reduces the cost of production. In this study the ram force has calculated experimentally for single hole
and multi-hole extrusion. The comparison of ram forces between the single hole and multi-hole extrusion
provides the inverse relation between the numbers of holes in a die and ram force. The experimental lengths of
the extruded products through the various holes of multi-hole die are different. It indicates that the flow pattern
is dependent on the material behavior. The micro-hardness test has done for the extruded products of lead
through multi-hole die. It is observed that the hardness of the extruded lead products from the central hole is
found to be more than that of the products extruded from other holes. The study suggests that multi-hole
extrusion can be used for obtaining the extruded products of lead with varying hardness. The micro-structure
study has done for the lead material before and after extrusion. It is observed that the size of grains of lead
material after extrusion is smaller than the original lead.
INVESTIGATION ON FRICTION STIR WELDING OF SIMILAR ALUMINIUM ALLOYS (AA6061) ...RenukaReddyVudumula
Friction Stir Welding (FSW) is the latest innovative and most complex process that is widely applied to the welding of lightweight alloys, such as aluminum alloys. this process provides the frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the work-pieces. The welding tool is positioned vertically on the material and then moved at welding speed along the joint line.
The plasticized material is transferred behind the tool, forming a welded joint.
In this research, a new approach for friction-stir welding of similar alloys of aluminum alloy 6061 and using cerium particles. The weld mechanical properties of the welds were investigated in this research. The effects of friction-stir welding process parameters such as tool rotational and traverse speeds were also examined. Mechanical properties of the welded parts will be examined by using tensile test, Impact test, and Hardness test.
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.
Effects of Cutting Tool Parameters on Surface Roughnessirjes
This paper presents of the influence on surface roughness of Co28Cr6Mo medical alloy machined
on a CNC lathe based on cutting parameters (rotational speed, feed rate, depth of cut and nose radius).The
influences of cutting parameters have been presented in graphical form for understanding. To achieve the
minimum surface roughness, the optimum values obtained for rpm, feed rate, depth of cut and nose radius were
respectively, 318 rpm, 0,1 mm/rev, 0,7 mm and 0,8 mm. Maximum surface roughness has been revealed the
values obtained for rpm, feed rate, depth of cut and nose radius were respectively, 318 rpm, 0,25 mm/rev, 0,9
mm and 0,4 mm.
Characterization and processing of friction stir welding on copper weldseSAT Journals
Abstract FSW(Friction Stir Welding) is a welding technology will be a part of different metals with sensible properties. During this paper, fsw attachment b/n steel, aluminum and copper plates with thicknesses of 3 millimeter was welded. Here we tend to had considered completely different completely different} materials with different combinations i.e copper and copper, copper and aluminum, aluminum & stainless steel, stainless steel & copper. Friction Stir Welding experiments were employed to get the good wieldable properties by maintaining the rpm speeds to 1120 revolutions per minute and attachment speed within the limit of 14-112 mm/min and here we can adjust the pin profile of the location respect to the line butt. Micro struc analysis can be done for examine the parent and the welded material. Cutting and sectioning of the welded pieces for metallographic analysis of the planes which are perpendicular for the attachment and the travelling direction & which is parallel to the friction welding was done. Here the mechanical properties of welding which was were determined by employing the same standard micro hardness and also tensile hardness testing and finding the maximum elongation of the metals to the properties of fsw. From experimental fsw process it can be found the pin profile and also the rotational speed, feed is an important in manufacturing of free welds in fsw of aluminum, copper and steel. Key Words: FSW, Aluminum, copper, stainless steel.
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…
EXPERIMENTAL AND ANALYSIS OF FRICTION DRILLING ON ALUMINIUM AND COPPERIAEME Publication
Friction drilling is a non-traditional hole making method that uses the heat generated from friction between a rotating conical tool and work piece to soften and penetrate the work material and generated a hole. Friction drilling is also called as thermal drilling, flow drilling, form drilling or friction stir drilling. High temperature and strain in friction drilling material properties and microstructure. The work piece enable softening, deformation and displacement of work material and
creates a bushing surrounding the hole without generating chip or waste material.
Finite element analysis on temperature distribution in turning process using ...eSAT Journals
Abstract The aim of this study is to create a finite element analysis simulation model in order to obtain solutions of the cutting forces, specific cutting energy and adequate temperatures occurring at different points through the chip/tool contact region and the coating/substrate boundary for a range of cutting tool materials and defined cutting conditions. Interfacial temperature in machining plays a major role in tool wear and can also result in modifications to the properties of the work piece and tool materials. As there is a general move towards dry machining, for environmental reasons, it is increasingly important to understand how machining temperature are affected by the process variables involved (cutting speed, feed rate, tool geometry, etc.) and by other factors such as tool wear. Index Terms: Turning Process, FEA, Analytical Modeling etc…
Effect of welding parameters and tool shape on properties of friction stir we...IJERA Editor
Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. It has many benefits when applied to welding of aluminum alloys. FSW process parameters such as welding speed, rotational speed and tool geometry play vital roles in the weld quality. The aim of this research is to investigate the effects of different welding speeds, rotational speeds and tool pin profile on the weld quality of a AA6061 aluminum alloy. A friction stir welding tool consists of rotating shoulder and pin that heats the working piece by friction and moves a softened alloy around it to form a joint. In this research work the effect of the tool shape and welding parameters (rotating speed and welding speed) on the mechanical properties of an aluminium plates will be investigated experimentally. The induced heat during the welding process played the main role in the mechanical and appearance of the joints, which is related to the welding parameters.
Optimization of friction stir welding parameters for joining aluminum alloy 6...eSAT Journals
Abstract This investigation represents the effects of parameters of friction stir welding on tensile strength and hardness during welding of Aluminium Alloy 6105. A fabricated FSWM set up was used for welding. A high carbon steel tool having 18 mm shoulder diameter and 5.5 mm pin diameter has been used. It was noted that for the friction stir welding of aluminium alloy 6105, maximum tensile strength is 0.0912 KN/mm2, which is obtain at 1250 rpm tool rotation speed, 25 mm/min welding speed and 00 tilt angle. It was also noted that the maximum vicker hardness is 65.7 which is obtain at 1550 rpm rotational speed, 35 mm/min welding speed and 0.50 tilt angle. Keywords: Friction stir welding, Aluminium alloy 6105, tensile strength, hardness, Taguchi L9 orthogonal array
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.
ANALYSIS OF TOOL USED FOR FRICTION STIR SPOT WELDING BY EXPLICIT MESHING SCH...vivatechijri
FSSW is an advanced and popular solid-state material welding method, which has achieved a
different variety of popularity in service in industries and automotive. FSSW method (technique) is used for joining
similar or dissimilar materials like aluminium, titanium, magnesium and copper alloys etc. This paper presents
finite element modeling of friction stir spot welding (FSSW) process using Abaqus/Explicit as a finite element
solver. Three-dimensional coupled thermal-stress model was used to calculate thermo-mechanical response of
FSSW process. The various factors such as rotational speed, transverse speed and profile of the tool plays a very
significant role in the joining quality of material using FSSW.
The main target of this analysis is to observe the variation of tool profile and welding quality of Ti 6Al 4V alloy
as the tool speed varies. Two Ti 6Al 4V were lapped and provided with support to the bottom of the plate known
as a back anvil to constrain the motion. This is where we analyzed the material flow due to friction of heat
generation in the weld zone. Ti 6Al 4V is one of the most commonly used materials and its applications, where
low density and excellent corrosion is applied in a wide range of resistance, are necessary in industries such as
aerospace industry and biomechanical, marine, chemical industries, gas turbine, etc.
Extrusion can be defined as the process of subjecting a material to compression so that it is forced to
flow through an opening of a die and takes the shape of the hole. Multi-hole extrusion is the process of
extruding the products through a die having more than one hole. Multi-hole extrusion increases the production
rate and reduces the cost of production. In this study the ram force has calculated experimentally for single hole
and multi-hole extrusion. The comparison of ram forces between the single hole and multi-hole extrusion
provides the inverse relation between the numbers of holes in a die and ram force. The experimental lengths of
the extruded products through the various holes of multi-hole die are different. It indicates that the flow pattern
is dependent on the material behavior. The micro-hardness test has done for the extruded products of lead
through multi-hole die. It is observed that the hardness of the extruded lead products from the central hole is
found to be more than that of the products extruded from other holes. The study suggests that multi-hole
extrusion can be used for obtaining the extruded products of lead with varying hardness. The micro-structure
study has done for the lead material before and after extrusion. It is observed that the size of grains of lead
material after extrusion is smaller than the original lead.
INVESTIGATION ON FRICTION STIR WELDING OF SIMILAR ALUMINIUM ALLOYS (AA6061) ...RenukaReddyVudumula
Friction Stir Welding (FSW) is the latest innovative and most complex process that is widely applied to the welding of lightweight alloys, such as aluminum alloys. this process provides the frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the work-pieces. The welding tool is positioned vertically on the material and then moved at welding speed along the joint line.
The plasticized material is transferred behind the tool, forming a welded joint.
In this research, a new approach for friction-stir welding of similar alloys of aluminum alloy 6061 and using cerium particles. The weld mechanical properties of the welds were investigated in this research. The effects of friction-stir welding process parameters such as tool rotational and traverse speeds were also examined. Mechanical properties of the welded parts will be examined by using tensile test, Impact test, and Hardness test.
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.
Effects of Cutting Tool Parameters on Surface Roughnessirjes
This paper presents of the influence on surface roughness of Co28Cr6Mo medical alloy machined
on a CNC lathe based on cutting parameters (rotational speed, feed rate, depth of cut and nose radius).The
influences of cutting parameters have been presented in graphical form for understanding. To achieve the
minimum surface roughness, the optimum values obtained for rpm, feed rate, depth of cut and nose radius were
respectively, 318 rpm, 0,1 mm/rev, 0,7 mm and 0,8 mm. Maximum surface roughness has been revealed the
values obtained for rpm, feed rate, depth of cut and nose radius were respectively, 318 rpm, 0,25 mm/rev, 0,9
mm and 0,4 mm.
Characterization and processing of friction stir welding on copper weldseSAT Journals
Abstract FSW(Friction Stir Welding) is a welding technology will be a part of different metals with sensible properties. During this paper, fsw attachment b/n steel, aluminum and copper plates with thicknesses of 3 millimeter was welded. Here we tend to had considered completely different completely different} materials with different combinations i.e copper and copper, copper and aluminum, aluminum & stainless steel, stainless steel & copper. Friction Stir Welding experiments were employed to get the good wieldable properties by maintaining the rpm speeds to 1120 revolutions per minute and attachment speed within the limit of 14-112 mm/min and here we can adjust the pin profile of the location respect to the line butt. Micro struc analysis can be done for examine the parent and the welded material. Cutting and sectioning of the welded pieces for metallographic analysis of the planes which are perpendicular for the attachment and the travelling direction & which is parallel to the friction welding was done. Here the mechanical properties of welding which was were determined by employing the same standard micro hardness and also tensile hardness testing and finding the maximum elongation of the metals to the properties of fsw. From experimental fsw process it can be found the pin profile and also the rotational speed, feed is an important in manufacturing of free welds in fsw of aluminum, copper and steel. Key Words: FSW, Aluminum, copper, stainless steel.
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…
EXPERIMENTAL AND ANALYSIS OF FRICTION DRILLING ON ALUMINIUM AND COPPERIAEME Publication
Friction drilling is a non-traditional hole making method that uses the heat generated from friction between a rotating conical tool and work piece to soften and penetrate the work material and generated a hole. Friction drilling is also called as thermal drilling, flow drilling, form drilling or friction stir drilling. High temperature and strain in friction drilling material properties and microstructure. The work piece enable softening, deformation and displacement of work material and
creates a bushing surrounding the hole without generating chip or waste material.
Finite element analysis on temperature distribution in turning process using ...eSAT Journals
Abstract The aim of this study is to create a finite element analysis simulation model in order to obtain solutions of the cutting forces, specific cutting energy and adequate temperatures occurring at different points through the chip/tool contact region and the coating/substrate boundary for a range of cutting tool materials and defined cutting conditions. Interfacial temperature in machining plays a major role in tool wear and can also result in modifications to the properties of the work piece and tool materials. As there is a general move towards dry machining, for environmental reasons, it is increasingly important to understand how machining temperature are affected by the process variables involved (cutting speed, feed rate, tool geometry, etc.) and by other factors such as tool wear. Index Terms: Turning Process, FEA, Analytical Modeling etc…
This is an overview of thermal metal removal processes under non conventional machining. this includes EDM, IBM, PAM, LBM, EBM .
Check this out, could be helpful!
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
International Journal of Engineering Research and Development is an international premier peer reviewed open access engineering and technology journal promoting the discovery, innovation, advancement and dissemination of basic and transitional knowledge in engineering, technology and related disciplines.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted
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.
Testing results of a multi-cavity mold for injection molding of MIM 4140 alloy are presented in the article. Recommendations for manufacturing of forming parts of the mold were given. Based on an implemented technological process of casting and subsequent laboratory researches an information was obtained about the condition of a casting (hardness on Super-Rockwell, shrinkage and quality of a surface layer of material before and after heat treatment). Calculated overall dimensions of the forming parts of the project mold will allow making forecast of shrinkage of MIM 4140 alloy after injection molding.
Modeling and Analysis for Cutting Temperature in Turning of Aluminium 6063 Us...IOSR Journals
Deviation in machining process due to the temperature influence, cutting force, tool wear leads to
highly inferior quality of finished product, especially in high speed machining operations where product quality
and physical dimensions seems to be meticulous. Moreover, temperature is a significant noise parameter which
directly affects the cutting tool and work piece. Hence the aim of this project work is to study the machining
effect on 6063 Aluminium alloy at varies combinations of process parameters such as speed, feed rate and depth
of cut; and also to determine the effect of those parameters over the quality of finished product. A L27
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(RSM) was used to analyse the machining effect on work material in this study. Using the practical data
obtained, a mathematical model was developed to predict the temperature influence and surface quality of
finished product. The ultimate goal of the study is to optimize the machining parameters for temperature
minimization in machining zone and improvement in surface finish.
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Study the Chip Tool Interactions & Tool Life in Plain Turining with High Velo...IJERA Editor
Introduction of green concepts in machining operations is being envisaged by introducing different echo
friendly cooling systems in the modern machine shops. The role of cutting fluids usage in metal cutting is
predominant as it influences the surface quality and production cost. The current work mainly focuses on the
study of chip tool interactions viz. contact pressure, temperature and chip flow pattern on the rake surface in
plain turning operation for different cutting parameters without any cooling medium and analyze the influence
of high pressure air jet as the cooling medium on the chip tool interactions like contact pressure reducing the
tool wear, cutting temperatures thereby increasing tool life.
1. Faculty of Engineering
Alexandria University
Investigation into Friction Drilling Process
By
Mohamed Alaa El-Dakrory
A thesis submitted to the
Production Engineering Department
in partial fulfilment of the requirements
for the degree of
Master of Science
Supervisors
Prof. Dr. Mohammad Yahya Al-Makky
Dr. Mohamed Abdelmoneim Daha
2. 1. Introduction to Friction Drilling
2. Thermal Friction DrillingTooling System
3. Finite Element Modeling of Friction Drilling
4. Experimental Setup
5. Results and Discussion
6. Conclusions
4. 4
Friction drilling is a hole making operation that is
based on a combination of axial force and relatively
high speed that generates local heat through friction
to penetrate and deform the work material into a
bushing shape.
5. a) The tip of the conical tool approaches and contacts
the workpiece
b) Friction on the contact surface, created from axial
force and relative angular velocity between tool
and workpiece, produces heat and softens the
workpiece material
c) The tool initially pushes the softened work-material
sideward and upward, then the tool pierce through
the workpiece
d) The tool moves further forward to push aside more
workpiece material and form the bushing using the
cylindrical part of the tool
e) The shoulder of the tool may contact the workpiece
to collar the back extruded burr on the bushing
5
7. Friction drilling makes a hole with a bushing length
that is 2 to 3 times the original sheet thickness in a
single step.
7
8. No material is removed during thread forming. The process
displaces the material to generate the thread
8
9. Different tool geometry
Higher heat generated and higher power consumption
Workpiece volume is constant
Small sheet thicknesses only (up to 12 mm).
Higher rotational speeds are required
TFD has an effect on friction drilled hole microstructure due
to heat
Chip-less process
9
13. Reduced material waste. All material from the drilled hole is
transformed to create the bushing.
Reduced inventory costs
13
Wide variety of Materials can be drilled
A single cycle operation suitable for
automated manufacturing
No disturbances caused by chips
14. The target material must be able to withstand the
added heat
not possible in massive material.
Not suitable for painted or coated materials
Small thicknesses only
14
18. Uniform tool with 100% friction contact area
Polygon tool with triangle, square or pentagon cross section so
that the friction contact area will vary 30%,50% or 75%
18
19. The tool holder holds the following:
Transmission shaft,
Cooling Disk,
Collet and a nut
19
21. Miller, et. al. (2012) Investigated the effect of
different parameters on cutting forces and torque.
Fernández et. al. (2013) analyzed, through controlled
tests at different rotational speeds and feed rates,
the friction drilling of austenitic stainless steel with
different thicknesses
Somasundaram (2011) applied response surface
methodology to develop a mathematical model for
hole quality in terms of roundness error
21
22. Miller S.F., Blau P.J. and Shih A.j characterized the micro-
structural alterations and subsurface micro-indentation
hardness changes produced as a result of the friction
drilling.
Miller S.F., TaoJ. and Shih A.J. [4] needed to generate a
cylindrical shaped bushing without significant radial
fracture or petal formation in brittle cast aluminum.
Miller S.F., Li R., Wang H. and Shih A.J. studied the wear of
carbide tool used for friction drilling of AISI 1015 steel
workpiece.
Lee S.M., Chow H.M., Huang F.Y. and Yan B.H. [10] used
tungsten carbide drills with physical vapor deposition
AlCrN andTiAlN coatings, and without coating to make
holes in AISI 304
22
23. Miller S.F. and Shih A.J. [7] investigated 3D finite
element modeling for friction drilling of Al6061-T6
work-material.RESULT
Qu J. and Blau P.J. [9] developed a new model for
thermal drilling useful for predicting the effective
friction coefficient and shear stresses
23
25. Introducing the process to the Egyptian local market
Manufacturing low cost tools
Investigate the effect of heat on the axial force,
torque , hole quality and materials microstructure.
25
26. Working on higher feed speeds and rotational speeds
is not always available,Thus working at lower speeds
and producing good quality holes is challenging
The cost of the tools and tool holders is very high, we
need to find an alternative.
26
27. Tool manufacturing
DAQ
Measure force and moment for different materials
FEA
Microstructural analysis
Hole quality evaluation
27
Low cost FD system with optimized
processing parameters
28. Designing and fabrication of friction drilling tools and cooling disk to
be used in experimental work.
With the aid of DAQ system, preparing a measuring setup to
measure the axial force and torque during the operation.
Developing a Finite Element Model for performance evaluation to
enhance input parameters selection.
Investigating the effect of the process working conditions on the
axial force, torque, tools as well as the products quality, aiming to
introduce the process to the Egyptian industries.
based on design of experiments methodology, conducting statistical
experiments for three different materials, to investigate the process
parameters and to validate the finite element model.
Studying the microstructure of the drilled specimens and the
microhardness due to the heat generation during the process
Investigating the approach to introduce the friction drilling process
to the Egyptian industries
28
29. 29
Property Material
Al 6061 St 1020 St.St.304
Yield Strength (Mpa) 274 294 215
Specific Heat Capacity J/g-°C) 0.896 0.519 0.5
Young’s Modulus (Gpa) 68.9 205 200
Poisson’s Ratio 0.33 0.29 0.29
ThermalConductivity (W/M-k) 167 51.9 16.2
30. 30
Effective Plastic Strain
Max.=3 mm/mm
Min.= 1 mm/mm
Temperature
Max.=308 Degree C
Min.= 20 Degree C
Effective Stress
Max.=680 MPa
Min.= 0 Mpa
42. Force Dynamometer Charge Amplifier DAQ Card
Model: KistlerType 9271 A
Force : Measuring range:
Fz: -5,000 N to 20,000 N
Sensitivity: 1.87 pC/N
Torque : Measuring range:
Mz : -1000 to 1000 Nm
Sensitivity: 1.62 pC/Ncm
Model: KistlerType :5017 B)
No. of channels: 8
Model: PCI-DAS 1602/16
12- bit A/D resolution.
330-kHz sample rate.
42
43. Process
Parameter
Levels
1 2 3
Rotational Speed
(A)(r.p.m)
2000 2500 3000
Feed speed (B)
(mm/min)
0.1 0.2 0.3
W/P Material (C) 1100 Aluminum 1.0303 Steel 304 Stainless Steel
43
The effect of three parameters; rotational speed (A), feed speed
(B), workpiece material (C) will be investigated .A full factorial
design of experiments 33 is chosen and each factor will have 3
levels; low level (level 1), medium level (level 2), and the high
level (level 3)
53. microstructure of the drilled holes is an important process aspects to be
investigated. Heat generated may reach up to 900 degrees Celsius in some
cases.
To get better surface finish the workpiece was submerged in epoxy to
increase the efficiency of the polishing process.
The specimens were chemically etched for microstructural observations.
Chemical etchants were applied to reveal the grain boundary and observe
the large plastic deformation of work-material
59
64. It is essential to know the hardness values of the work
piece, as hardness is the property of a material that
enables it to resist plastic deformation, usually by
penetration
The testing samples were tested byVickers hardness
tester.The hardness of the drilled material was
changing in dependence of measuring distance from
the heat influenced places
70
65. A 2mm step was taken from the hole edge to
investigate the effect of heat on the microhardness
along the hole edge and away from the hole edge
71
68. Deficiencies in the bushing or the collar quality will affect the
thread forming operation and the thread dimensions.
Radial drilling forces and hear generated may have a
significant effect on the collar quality,
74
69. 0.1 mm/sec 0.2 mm/sec 0.3 mm/sec
75
• At low rotational speed (2000 rpm) the formed collar was
ruptured with rough surface due to high friction
70. • Depending on the increase in drilling rotational speed, the fast
decrease in radial forces made sure that a smooth washer is
formed due to less effect on washer geometry
76
0.1 mm/sec 0.2 mm/sec 0.3 mm/sec
71. Another aspect to be considered when studying the
hole geometry of friction drilled holes is bushing
formation
According to Flowdrill Company [2], the generated
bushing in friction drilling is assumed to be 2 or three
times the original sheet thickness
The process main goal is to obtain as long bushing as
possible because this bushing will be used in
threading
77
72. 78
Effect of Rotational speed on bush length (2000 rpm, stainless steel)
• At lower speeds the heat generated is not enough to
decrease the yield strength of the material and so, the
bushing length is shorter. Also radial force increases
depending on higher axial force due to low temperatures.The
increase in radial force ruptures the edges of the hole and
increases petal during the formation of bushing.
73. At high speeds the heat generated increases which
means that the yield stress of the workpiece
decreases and material suffers less deformation thus,
the extrusion length increases
79
75. Friction drilling can be performed at low feed speeds
ranges (0.1- 0.3 mm/sec)
Feed speed has greater influence on the cutting forces
than rotational speeds for the investigated range.
In friction drilling, not only the material hardness and
carbon content can affect the force values, but also the
material thermal properties.The force required to drill
Stainless steel is lower than that of 1.0303 Steel, the main
reason for this phenomenon is the thermal conductivity
of both materials (75 wm-1k-1 for Steel and 17.6 wm-1k-1
for Stainless steel) which means that Stainless steel will
not dissipate heat easily, which in return will decrease the
required drilling forces.
81
76. Although Stainless steels are considered hard-to-machine
materials, with respect to friction drilling , 304 Stainless
steel needs lower forces to be drilled because of its high
formability
Friction Drilling has large influence on the microstructure
of the drilled holes. In most cases finer grains are
produced as a result of normalization.
The microhardness of most specimens has increased after
friction drilling as a result of the new fine grains structure.
Locally manufactured tools are cost effective and can
perform friction drilling and produce good quality holes.
However, the main limitation was the tool lifetime which
was very short compared to Flowdrill tool
82
77. Better finite element model with improved accuracy can
be developed with an emphasis on simulating the effect
of heat on microstructure alterations.
Effect of preheating the workpiece before drilling needs
to be observed as it may decrease the drilling forces and
improve the hole quality
Drilling brittle materials is challenging and needs to be
investigated
Manufacturing of friction drilling tools with longer tool
life
Correlating the effect of sheet thickness to the ratio
between the hole diameter and bushing length. (d/t).
83