IJRMET VOL. 7, ISSUE 2, MAY - OCT 2017 ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print) www.ijrmet.com 16 INTERNATIONAL JOURNAL OF RESEARCH IN MECHANICAL ENGINEERING & TECHNOLOGY Experimental Investigation and Finite Element Analysis of Fristion Stir Welding of Two Disimilar Materias Dr. Ch.S.Naga Prasad Dept. of Mechanical Engineering, GIITS Engg. College, Aganampudi, Visakhapatnam (DT), AP, India Abstract Friction Stir Welding (FSW), invented by Wayne Thomas at TWI (The Welding Institute) Ltd in 1991, overcomes many of the problems associated with traditional joining techniques. FSW is a solid-state process which produces welds of high quality in difficult-to-weld materials such as aluminum, and is fast becoming the process of choice for manufacturing lightweight transport structures such as boats, trains and aero-planes. The main objective of this project is to investigate the hardness and strength of the friction stir welded aluminum alloy and copper with different speeds by taking tapper tool pin profile. The material of tool is HCHCr (High Carbon High Chromium). Experimental investigation is performed on CNC milling machine and cutting tool speed 700 rpm. FEA analysis is performed for friction stir welding of aluminum 6061 and aluminum 5083 at 700rpm speed using ANSYS. Thermal and structural analysis is performed. A parametric model with the weld plates and cutting tool is done in Pro/Engineer. The effects of taper and round tool pin profiles on the friction stir welding are considered for analysis. Keywords FSW, Alumnium Alloy and Copper I. Introduction Friction Stir Welding is the most recent upgrade to the Space Shuttle’s gigantic External Tank, the largest element of the Space Shuttle and the only element not reusable. The new welding technique—being marketed to industry—utilizes frictional heating combined with forging pressure to produce high-strength bonds virtually free of defects. Friction Stir Welding transforms the metals from a solid state into a “plastic-like” state, and then mechanically stirs the materials together under pressure to form a welded joint. Invented and patented by The Welding Institute, a British research and technology organization, the process is applicable to aerospace, shipbuilding, aircraft and automotive industries. One of the key benefits of this new technology is that it allows welds to be made on aluminum alloys that cannot be readily fusion arc welded, the traditional method of welding. In 1993, NASA challenged Lockheed Martin Laboratories in Baltimore, Md., to develop a high-strength, low-density, lighterweight replacement for aluminum alloy Al 2219–used on the original Space Shuttle External Tank. Lockheed Martin, Reynolds Aluminum and the labs at Marshall Space Flight Center in Huntsville, Ala., were successful in developing a new alloy known as Aluminum Lithium Al-Li 2195, which reduced the weight of the External Tank by 7,500 pounds (3,402 kilograms). Today, the External Tank project uses the new alloy to build the Shuttle’s Super Lightweight Tanks. The lithium in the new lighter-weight material— aluminum lithium alloy Al-Li 2195—made the initial welds of the External Tank far more complex. Fig. 1: Friction Stir Welding II. Literature Review Modern structural application demands reduction in both the weight and as well as cost of the fabrication and production of materials. Aluminum alloys are the best choice for the reduction of weight, cost and replacing steels in many applications and Friction Stir Welding (FSW) process efficient and cost effective process. FSW is solid state welding process in which material is not melted during welding process so it overcomes many welding defects compared to conventional fusion welding process which is initially used for low melting materials. This process is initially developed for low melting materials like Aluminum, Magnesium, Zinc but now process is useful for high melting materials like steel and also for composites materials. The present study describes the effect of FSW process involving butt joining of similar Aluminum alloy combinations of AA6351 with AA6351 and dissimilar Aluminum ally combinations of AA6351 with AA5083 on the tensile, hardness and impact behavior. III. Introduction to CAD/CAE Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and design-documentation. A. Introduction to Pro-Engineer Pro/ENGINEER Wildfire is the standard in 3D product design, featuring industry-leading productivity tools that promote best practices in design while ensuring compliance with your industry and company standards. Integrated Pro/ENGINEER CAD/CAM/CAE solutions allow you to design faster than ever, while maximizing innovation and quality to ultimately create exceptional products. Different modules in pro/engineer Part design, Assembly, Drawing& Sheet metal. B. Introduction to Finite Element Method Finite Element Method (FEM) is also called as Finite Element Analysis (FEA). Finite Element Method is a basic analysis
Transcript
IJRMET Vol. 7, IssuE 2, May - ocT 2017 ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print)
w w w . i j r m e t . c o m 16 INterNatIONal JOurNal Of reSearch IN MechaNIcal eNgINeerINg & techNOlOgy
Experimental Investigation and Finite Element Analysis of Fristion Stir Welding of Two Disimilar Materias
Dr. Ch.S.Naga PrasadDept. of Mechanical Engineering, GIITS Engg. College, Aganampudi, Visakhapatnam (DT ), AP, India
AbstractFriction Stir Welding (FSW), invented by Wayne Thomas at TWI (The Welding Institute) Ltd in 1991, overcomes many of the problems associated with traditional joining techniques. FSW is a solid-state process which produces welds of high quality in difficult-to-weld materials such as aluminum, and is fast becoming the process of choice for manufacturing lightweight transport structures such as boats, trains and aero-planes. The main objective of this project is to investigate the hardness and strength of the friction stir welded aluminum alloy and copper with different speeds by taking tapper tool pin profile. The material of tool is HCHCr (High Carbon High Chromium). Experimental investigation is performed on CNC milling machine and cutting tool speed 700 rpm. FEA analysis is performed for friction stir welding of aluminum 6061 and aluminum 5083 at 700rpm speed using ANSYS. Thermal and structural analysis is performed. A parametric model with the weld plates and cutting tool is done in Pro/Engineer. The effects of taper and round tool pin profiles on the friction stir welding are considered for analysis.
KeywordsFSW, Alumnium Alloy and Copper
I. IntroductionFriction Stir Welding is the most recent upgrade to the Space Shuttle’s gigantic External Tank, the largest element of the Space Shuttle and the only element not reusable. The new welding technique—being marketed to industry—utilizes frictional heating combined with forging pressure to produce high-strength bonds virtually free of defects. Friction Stir Welding transforms the metals from a solid state into a “plastic-like” state, and then mechanically stirs the materials together under pressure to form a welded joint. Invented and patented by The Welding Institute, a British research and technology organization, the process is applicable to aerospace, shipbuilding, aircraft and automotive industries. One of the key benefits of this new technology is that it allows welds to be made on aluminum alloys that cannot be readily fusion arc welded, the traditional method of welding. In 1993, NASA challenged Lockheed Martin Laboratories in Baltimore, Md., to develop a high-strength, low-density, lighterweight replacement for aluminum alloy Al 2219–used on the original Space Shuttle External Tank. Lockheed Martin, Reynolds Aluminum and the labs at Marshall Space Flight Center in Huntsville, Ala., were successful in developing a new alloy known as Aluminum Lithium Al-Li 2195, which reduced the weight of the External Tank by 7,500 pounds (3,402 kilograms). Today, the External Tank project uses the new alloy to build the Shuttle’s Super Lightweight Tanks. The lithium in the new lighter-weight material— aluminum lithium alloy Al-Li 2195—made the initial welds of the External Tank far more complex.
Fig. 1: Friction Stir Welding
II. Literature Review Modern structural application demands reduction in both the weight and as well as cost of the fabrication and production of materials. Aluminum alloys are the best choice for the reduction of weight, cost and replacing steels in many applications and Friction Stir Welding (FSW) process efficient and cost effective process. FSW is solid state welding process in which material is not melted during welding process so it overcomes many welding defects compared to conventional fusion welding process which is initially used for low melting materials. This process is initially developed for low melting materials like Aluminum, Magnesium, Zinc but now process is useful for high melting materials like steel and also for composites materials. The present study describes the effect of FSW process involving butt joining of similar Aluminum alloy combinations of AA6351 with AA6351 and dissimilar Aluminum ally combinations of AA6351 with AA5083 on the tensile, hardness and impact behavior.
III. Introduction to CAD/CAEComputer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and design-documentation.
A. Introduction to Pro-EngineerPro/ENGINEER Wildfire is the standard in 3D product design, featuring industry-leading productivity tools that promote best practices in design while ensuring compliance with your industry and company standards. Integrated Pro/ENGINEER CAD/CAM/CAE solutions allow you to design faster than ever, while maximizing innovation and quality to ultimately create exceptional products.Different modules in pro/engineerPart design, Assembly, Drawing& Sheet metal.
B. Introduction to Finite Element MethodFinite Element Method (FEM) is also called as Finite Element Analysis (FEA). Finite Element Method is a basic analysis
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technique for resolving and substituting complicated problems by simpler ones, obtaining approximate solutions Finite element method being a flexible tool is used in various industries to solve several practical engineering problems. In finite element method it is feasible to generate the relative results.
IV. Results and Discussions
A. Models of Steam Boiler Using Pro-E Wildfire 5.0
1. FSW 3D Model
Fig. 1:
B. FSW 2D Model
Fig. 2:
B. Static Analysis of Friction Stir Welding
1. Deformation
Fig. 3:
2. Stress
Fig. 4:
3. Strain
Fig. 5:
C. Modal Ananlysis of FSW
1. Deformation 1
Fig .6:.
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2. Deformation 2
Fig. 7:
3. Deformation 3
Fig. 8:
V. Experimental SetupExperimental investigation is done to verify the mechanical properties of friction stir welding of aluminum alloy 5083 and copper. The properties investigated are tensile strength and hardness compared before and after welding. The welding is done on Vertical CNC machine.
In this work, the process was done using a vertical milling machine having automatic feed. The tool rotational speeds and the feeds were set accordingly and the respective experiments were conducted. The tool rotational speeds considered were 700rpm’s and the feed rate considered is 20 mm/min respectively.
Fig. 9:
A. Machine used for Friction Stir Welding
Fig. 10:
Fig. 11:
B. Final Part
Fig. 12:
C. Tensile TestTensile testing, also known as tension testing, is a fundamental materials science test in which a sample is subjected to a controlled tension until failure. The results from the test are commonly used to select a material for an application, for quality control, and to predict how a material will react under other types of forces. Properties that are directly measured via a tensile test are ultimate tensile strength, maximum elongation and reduction in area. From these measurements the following properties can also be determined young’s modulus, poisons ratio, yield strength and strain-hardening characteristics.
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VII. ConclusionIn this project cutting tool taper is designed for doing Friction Stir Welding of two dissimilar materials Aluminum alloy 5083 and aluminum alloy6061 running at speeds of 700rpm. Modeling is done in Pro/Engineer. Structural and modal analysis is performed on the circular and taper tool to verify the deformation and stresses. By observing the results, stresses produced are decreased circular tool. Two plates of the aluminum alloy 5083 and aluminum alloy 6061 are welded experimentally on a vertical CNC machine using 700rpm speed for circular cutting tool. Tensile strength, micro structure, impact and hardness are evaluated after welding. By observing the tensile test results, ultimate tensile strength is decreasing by increased. By observing the hardness test results, the yield stress value 51.43MPa.
References [1] Dhaval S. Chaudhari,"Joining of Aluminum to Copper by
Friction Stir Welding", International Journal of Innovative Research in Advanced Engineering (IJIRAE) 2014; 1 (8): pp. 18-21.
[2] Sefika Kasman, Zafer Yenier,"Analyzing dissimilar friction stir welding of AA5754/AA7075", Int J Adv Manuf Technol 2014; 70: pp. 145-156.
[3] Mukuna P.Mubiayi, Esther T. Akinlabi,"Friction stir welding of dissimilar materials between Aluminium Alloys and Copper: An overview", Proceedings of the world congress on engineering 2013 Vol 3, WCE, July 3-5, London, U.K.
[4] N.T. Kumbhar, K.Bhanumurthy,"Friction stir welding of Al 6061 Alloy", Asian J. Exp. Sci., Vol. 22, No. 2, pp. 63-74, 2008.
[5] M.Sivsshanmugam, S.Ravikumar, T.Kumar, V.Seshagiri, D.Muruganandam,"A Review on friction stir welding for aluminium alloys", IEEE, pp. 216-221A, 2010.
[6] M. Jayaram, R. Sivasubramanian, V. Balasubramanian, A K Lakshminarayanan,"Optimization of process parameters for friction stir welding of cast aluminium alloy A319 by Taguchi method", Journal of scientific and industrial research, pp. 36-43, 2009.
[7] Galvao, D. Verdera, D. Gesto, A. Loureiro D. M. Rodrigues,"Analyzing the challenge of aluminium to copper FSW", CEMUC, Portugal.
[8] M. Muthukrishnan, K.Marimuthu,"Some studies on mechanical properties of friction stir butt welded Al-6082-T6 plates", IEEE; pp. 269-273.
[9] Umar Bin Patthi, Mokhtar Awang,"Friction stir welding of aluminium 6092/sic/25p/t6 Metal matrix composite: Its microstructure evolution and mechanical properties", IEEE. welded dissimilar aluminium alloy, IEEE.
DR.CH.S.Naga Prasad received his M.Tech Degree on Heat power Refrigerator and AC from JNTU, Anantapur in 2002 and Ph.D on IC Engines (Thermal Engg) from JNTU, Hyderabad in 2011. He is currently working as Professor & Principal in Gonna Institute of Information Technology and sciences, Aganampudi, Visakhapatnam, A.P, INDIA.
