Informatics Publishing Limited

J. Jayapriya ¹, D. Muruganandam ¹, K. Thirusangu ², Sushil Lal Das ³

Affiliations
1 Research Scholar, Sathyabama University, Chennai119
2 Department of Mathematics, S.I.V.E.T College, Chennai–73
3 Department of Mechanical Engineering, Jeppiaar Engineering College, Chennai–119

Abstract

In this paper the numerical data involved during the processes of welding is stored over a graph structure and its changes during compression are analyzed by using max/mini edge labeling.

Keywords

Graph, Function, Labeling, Alloy, Welding, Max/mini Labeling

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D. Muruganandam ¹, C. Balasubramaniyan ², B. Gokulachander ²

Affiliations
1 Sri Sairam Engineering College, Chennai – 600044, Tamil Nadu, IN
2 AMET University, Chennai – 603112, Tamil Nadu, IN

Abstract

Objective: Friction Stir Welding (FSW) is a relatively new solid state welding technique for similar and dissimilar materials, especially on current interest with aluminum and magnesium alloys. Methods/Analysis: The Friction Stir Welding of aluminum alloys with magnesium alloys are reviewed on this paper. The basic principles of FSW are described, followed by process parameters study which affects the weld strength. Findings: The microstructure and the likelihood of defects also reviewed. Tensile strength properties attained with different process parameters are discussed. Conclusion/Application: It is demonstrated that FSW of aluminum and magnesium alloy is becoming an emerging technology with numerous commercial applications.

Keywords

Aluminum Alloys, Friction-Stir Welding, Magnesium Alloys, Microstructure, Tensile Strength

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L. A. Kumaraswami Dhas ¹, D. Raguraman ², D. Muruganandam ², B. Senthilkumar ²

Affiliations
1 Department of Mining Machinery Engineering, Indian School of Mines, Dhanbad-826 004, Jharkhand, IN
2 Department of Production Engineering, Sri Sairam Engineering College, Chennai-600 044, Tamil Nadu, IN

Abstract

Background/Objectives: The objective of this paper is on developing a thermo-mechanical model to predict the thermal histories of the FSW butt joint of AA 6061-AZ61. Methods/Statistical Analysis: The FEM model is developed for the temperature and residual stress characteristics of the weld material. The friction serves as the heat source which exists between the pin and plate as well as the shoulder and plate. To understand the dynamics of the Friction Stir Welding thermal and residual effects,the thermal history and the evolution of longitudinal, lateral residual stresses in the friction stirred weld are simulated using ANSYS. Findings: The temperature influences on Von-mises stress and strain on the different zones are analyzed. The contour technique using Coordinate Measuring Machine (CMM) is used to measure the residual stress of the welded plate.It is found that the proposed model is correlated with experimental result. Application/ Improvements: The developed FEM model can be used as one of the tool for correlating the temperature and residual stresses on the weld zone. The CMM also can be used to predict the residual stresses through contour measurement.

Keywords

Finite Element Method, Friction Stir Welding, Residual Stress, Temperature Distribution,Thermo-Mechanical Model

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L. A. Kumaraswami Dhas ¹, D. Raguraman ², D. Muruganandam ², B. Senthilkumar ²

Affiliations
1 Department of Mining Machinery Engineering, Indian School of Mines, Dhanbad-826 004, Jharkhand, IN
2 Department of Production Engineering, Sri Sairam Engineering College, Chennai-600 044, Tamil Nadu, IN

Abstract

Background/Objectives: The objective of this paper is on developing a thermo-mechanical model to predict the thermal histories of the FSW butt joint of AA 6061-AZ61. Methods/Statistical Analysis: The FEM model is developed for the temperature and residual stress characteristics of the weld material. The friction serves as the heat source which exists between the pin and plate as well as the shoulder and plate. To understand the dynamics of the Friction Stir Welding thermal and residual effects,the thermal history and the evolution of longitudinal, lateral residual stresses in the friction stirred weld are simulated using ANSYS. Findings: The temperature influences on Von-mises stress and strain on the different zones are analyzed. The contour technique using Coordinate Measuring Machine (CMM) is used to measure the residual stress of the welded plate.It is found that the proposed model is correlated with experimental result. Application/ Improvements: The developed FEM model can be used as one of the tool for correlating the temperature and residual stresses on the weld zone. The CMM also can be used to predict the residual stresses through contour measurement.

Keywords

Finite Element Method, Friction Stir Welding, Residual Stress, Temperature Distribution,Thermo-Mechanical Model

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D. Muruganandam ¹, Sushilal Das ²

Affiliations
1 Sathyabama University, Chennai-119, Tamil Nadu, IN
2 Jeppiar Engineering College, Chennai-119, Tamil Nadu, IN

Abstract

Friction stir welding has proved as one of the best solid state joining method for materials such as aluminium and magnesium. Some of the aluminium alloys which are not weldable (Al-Cu, Al-Zn-Mg alloys) by fusion welding techniques, and or produce defects and reduce the mechanical properties, could be welded using friction stir welding (FSW) successfully with excellent joint efficiencies. However, the process parameters exert significantly on the properties of weldment and therefore needs to be investigated thoroughly.

In this study, friction stir welding of dissimilar aluminium alloys AA2024&AA7075 are selected. The welding process were conducted on varying the welding process parameters such as Tool rotation speed (rpm), Welding speed (mm/min), Downward force (kN) and Tool pin profiles. The mechanical properties and bending behavior on welded plates were studied and compared with the base metal. Experiments were performed with rotational speeds 600, 700, 800 and 900 rpm at six welding speeds i.e. 20, 30, 40, 50, 60 and 70mm/min keeping constant axial load 2.5kN and tool tilt angle 0°. It was found that there is no defect concentration for the tool speed rotation of 600 rpm, welding speed 30 mm/min and 2.5 kN downward force. Tensile and bend test values were also reported.

Keywords

Friction Stir Welding, Tool Rotation Speed (RPM), Welding Speed (mm/min), Downward Force (KN), Tool Pin Profiles, Aluminium Alloy 2024 and 7075.

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J. Jayapriya ¹, D. Muruganandam ², S. Gopalakrishnan ², S. Briolin Nayagam ³

Affiliations
1 Department of Mathematics, Sathyabama University, Chennai - 600119, Tamil Nadu, IN
2 Department of Production Engineering, SriSairam Engineering College, Chennai - 600 044, Tamil Nadu, IN
3 Department of Computer Science, Jeppiaar Institute of Technology, Sriperumbudur, Kanchipuram - 631604, Tamil Nadu, IN

Abstract

Friction stir welding is solid state joining process where the energy efficiency is dependant on the selection of tool geometry. The objective of this work is to reduce time consumption in calculating tool geometric parameters using C program. As the tool being of different geometry in concern with different complex operation, the energy generated and the temperature distribution which influenced by efficient energy is to be calculated. The calculation is performed based on the machining different work pieces by adjusting tool parameters of aluminium alloys such as Al6061-T6, Al22024-T6, Al7075-T6. Six different cases had been generated in our work for each Aluminium alloy where different RPM (Rotation Per Minute) such as 200, 400, 600, 800, 1000, 1200 was maintained and compared to translational speed and applied normal force. The Energy and Maximum Temperature obtained using Taper Model and the Cylindrical model is compared based on the data processed during the machining. The proposed energy model equation is helpful in computing these data. Manual calculation in these equation may lead to large consumption. Thus the different tool parametric value can be easily generated by coding these equation in C program and feeding necessary input parameters from users. Thereby it generates the different values at faster rate. From this experiment, it is found that abrupt changes in the process may lead influence the efficiency of welding the material and may affect it. Larger data regarding the tool parameter can be processed easily at less time using C. Different tools have different parametric changes and thereby having knowledge over its parameters may not affect the work pieces. C program help to generate these data. Further improvement can be made by doing same study over different other tools and by coding these different values calculated maybe helpful in tool selection. The study can also be made over similar other welding processes too and also help in prevention of damage of different work pieces.

Keywords

C-Programming, Energy Model, Friction Stir Welding, Taper Tool, Temperature Model

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D. Muruganandam ¹, S. Ravikumar ², V. Seshagiri Rao ³, Sushil Lal Das ⁴

Affiliations
1 Dept. of Mechanical Engg., Dhanish Ahmed College of Engg., Chennai, IN
2 Dept. of Mechanical and Production Engg, Sathyabama University, Chennai, IN
3 Dept. of Mechanical Engg., St. Joseph College of Engg., Chennai, IN
4 Jeppiaar Engg. College, Chennai, IN

Abstract

Aluminium alloys have gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to weight ratio and good corrosion resistance. Modern structural concepts demand reductions in both the weight as well as the cost of the production and fabrication of materials. Therefore welding processes have proven more attractive, and there is an urgency to study their potential. Compared to the fusion welding processes that are routinely used for joining structural aluminium alloys, friction stir welding (FSW) process, an emerging solid state joining process was invented in 1991 by TWI, in which the material that is being welded does not melt and recast. The major advantage in FSW process is that the maximum temperature reached is less than 80% of the melting temperature, i.e. the joint is performed in the solid-state and excessive micro structural degradation of the weld zone is avoided. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force etc., and tool pin profile play a major role in deciding the joint strength. This paper focuses on mechanical properties evaluation and predicting the process parameters in varying rotational and welding speeds of friction-stir welding for the dissimilar precipitation hardenable aluminium alloys ie., between 6xxx (Al-Mg-Si) and 7xxx (Al-Zn-Mg).

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