International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

RESEARCH AND ANALYSIS OF FSW TO SUGGEST OPTIMUM

TOOL SHAPE

G. Ragni 1, S.V.S Rama Krishnam Raju2, G Nagendra Krishna3, Godi Subba Rao4,
1
2
3
4

Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India
Professor , Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India
Assistant professor , Department of Mechanical Engineering, Hyderabad Institute of Technology and Management,Hyderabad,India
professor , Department of Mechanical Engineering, Hyderabad Institute of Technology and Management,Hyderabad,India

Abstract
A319 Aluminum alloy has gathered wide acceptance in the fabrication of light weight structures required a high strength
to weight ratio. Compared to fusion welding processes that are routinely used for joining structural aluminum alloys,
friction stir welding process is an emerging solid state joining process in which the material that is being welded does not
melt and recast. This process uses non-consumable tool to generate frictional heat in the butting surfaces. The welding
parameters tool pin profile plays a major role in deciding welding quality.
In this project an attempt is made to understand the effect of welding speed and tool pin profile on FSP zone formation
in A319 alloy. Four different tool pin profiles are used to fabric the welding joints. Those profiles are 1.Stright cylindrical,2.Tapered cylindrical,3.Thread, 4.Hexagonal.In this project we are also doing coupled field analysis for both cutting
toolsand welding plates.
We are also doing experimental work by using CNC milling machine. In that we are preparing fixture, cutting tools and
plates. We are conducting this experimental work for 4 different tools.
For modeling we are using Pro/Engineer software, for analysis ANSYS.

*Corresponding Author:
G. Ragni ,
Research Scholar,
Department 0f Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
Published: July 04, 2015
Review Type: peer reviewed
Volume: II, Issue : IV

Citation: G.Ragni,Research Scholar (2015) RESEARCH

AND ANALYSIS OF FSW TO SUGGEST OPTIMUM TOOL
SHAPE

INTRODUCTION TO EDM

FRICTION STIR WELDING

Friction stir welding has enjoyed worldwide interest

since its inception because of its advantages over traditional joining techniques.
A rotating tool with pin and shoulder is inserted in the
material to be treated, and traversed along the line of interest (Figure 2.1). During FSW, the area to be processed
and the tool are moved relative to each other such that
the tool traverses with overlapping passes until the entire
selected area is processed to a fine grain size. The rotating tool provides a continual hot working action, plasticizing metal within a narrow zone while transporting metal
from the leading face of the pin to its trailing edge. The
processed zone cools without solidification, as there is no
liquid a defect-free re- crystallized fine grain microstructure is formed.

Although weldingisa promising joiningprocess in terms of

fabricationcost, the traditionalarcweldingmethodsarenotcapableof producing soundwelds due toMetallurgical
problems.However,FSW process which was recently
invented enables the welding of high performanceAlalloysthatarecustomarily
usedinaircraftstructures.This
chapterdealswithdesignationofAluminum alloys, description of welding, descriptionofFSW process,description ofcommercialFEA softwaresand previouswork on simulationof FSW.

CLASSIFICATION OF WELDING:
(a) Arc welding
(b) Gas Welding
(c) Resistance Welding
(d) Thermit Welding
(e) Solid State Welding
(f) Newer Welding
(g) Related Process

Fig: Schematicoffrictionstirwelding
Essentially, FSW is a local thermo-mechanical metal
working process with additional adiabatic heating from
metal deformation that changes the local properties without influencing properties in the remainder of the structure. A processed zone is produced by movement of material from the front of the pin to the back of the pin. As
mentioned later, the pin and shoulder of the tool can be
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International Journal of Research and Innovation (IJRI)

modified in a number to ways to influence material flow

and micro-structural evolution. Friction Stir welding
has opened up a new process for inducing directed, localized, and controlled materials properties in any arbitrary
location and pattern to achieve revolutionary capability
in high value-added components. Friction stirwelding
provides the ability to thermo-mechanically process selective locations on the structures surface and to some
considerable depth (>25mm) to enhance specific properties. Research is being increasingly focused on this aspect of the technology for use with automotive alloys. For
example, Cast aluminum alloys, such as A319, are used
for suspension and drive line components in automobiles.
Materialunderthe toolshoulderelevatesthestrengthof thematerial decreases.

3. Veryfine grainsize inthe stirredregion.

4. Randomdisorientation ofgrain boundariesinstirredregion.
5. Mechanicalmixing of thesurfacelayer.
6. Controlledflow of material.
7. Highjointefficiencies(competitive withriveting andbonding)
8. Excellent mechanical properties as demonstrated by
fatigue,tensile and bend tests.
9. Robustprocess
10. Environmentally friendly process
11. Nofumes, No porosity
12. One tool can typically be used for upto 1000m of joint
length
13. Nofiller wire
14. No gasshielding
15. No grinding,brushing or pickling required in mass
production.

APPLICATIONS
Shipbuilding and MarineIndustries
The ship building and marine industries are two of the
first industry sectors which have adopted the process for
commercial applications. The process is suitable for the
following applications:
Figure1.1frictionstirweldingprocess:
(a)rotatingtoolprior tocontact withtheplate;
(b)toolpincontactsplatecreatingheat;
(c)Shoulderoftool contactsplaterestrictingfurtherpenetrationwhileexpandingthehotzone;
(d)platemovesrelativetorotatingtoolcreatingafullyre-crystallized,fine grainmicrostructure.
Oneofthekey elementsintheFSW processistheheatgeneratedat theinterfacebetweenthetoolandtheworkpiecewhichisthedrivingforce tomake theFSW processsuccessful.
The heatfluxmustbe keptmaximum suchthatthe temperature intheworkpieceishighenough, sothatthe materialissufficiently softfor the pintostirbutlowenoughsothatthe
materialdoesnotmelt.
The maximum temperature created by FSW processrangesfrom 80% to 90% of the melting temperatureof the workpiece material, as measured by Tangetal.
andColegroveetal.,so that welding defects and large distortion commonly associated with fusion welding are minimized or avoided. The heat fluxinfriction stir processing
isprimarily generated by the friction and the deformation
process. Thisheatisconductedtoboththe tooland thework
piece.Theamount of the heatconductedinto the work piece
dictatesa successful process which is defined by the quality, shape and microstructure of the processed zone,as
well as theresidualstressand the distortion of the work
piece.The amount of the heat gone to the tool dictates
the life of the tool and the capability of the tool to produce agood processed zone. For instance, insufficient
heat from the friction could lead to breakage of the pin of
the tool since thematerial is not soft enough. Therefore,
understanding the heat transfer aspect of the friction stir
welding is extremely important, not only for the science
but also for improving the process.

Panels for decks, sides, bulkheads and floors

Hulls and superstructures
Helicopter landing platforms
Marine and transport structure

Aerospace industry
At present the aerospace industry uses FSW for welding prototype and production parts. Opportunities exist to weld skins to spars, ribs, and stringers for use in
military and civilian aircraft. The Eclipse 500 aircraft, in
which 60% of the rivets are replaced by friction stir welding, is now in production. The friction stir welding process
can therefore be considered for:

Wings, fuselages, empennages

Cryogenic fuel tanks for space vehicles
Aviation fuel tanks
Repair of faulty MIG welds

PART MODELING IN PRO/ENGINEER

Circular tool

ADVANTAGESOFFRICTIONSTIRWELDING
The followingaretheunique featuresof frictionstir welding.
1. Lowamountof heatgenerated.
2. Extensive plastic flowofmaterial.
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International Journal of Research and Innovation (IJRI)

HEXAGONAL TOOL

Contact area:
Cylindrical = 117.8m2
Tapered = 102.22 m2
hexagon = 118.6 m2
Threaded = 158.69 m2
1.HEAT FLUX for circular :
Heat flux = q = KA(T )/d
T = change in temperature
T2 = 973
T1 = 323
T =650K
q = 26117.8650/85.75=1990820/85.75=23216.559
heat flux = q/A=23216.559/5133.57=4522.497 W

TAPPERD CYLENDER TOOL

2.HEAT FLUX for tapered cylinder

Heat flow = q= KA(T )/d
T=650
q = 26102.22650/85.75=20145.982
heat flux = q/A=20145.982/5117.63=3936.584 W
3.HEAT FLUX for hexagon
Heat flow = q= KA(T )/d
q = 26118.6650/85.75=23374.22741
heat flux = q/A=23374.2274/5151.84=4537 W

CERCULER WITH THREADS TOOL

4.HEAT FLUX for threaded

Heat flow = q= KA(T )/d
q = 26158.69650/85.75=31275.346
heat flux = q/A=31275.346/5185.58=6031.214W
A= contact area
T = temperature difference
D = distance of heat flow

COUPLED FIELD ANALYSIS OF STRAIGHT CYLINDRICAL

ASSEMBLY

The above image shows imported model

FSW tools
Circular/cylindrical S.A =5133.57 sq mm.
Tapered cylinder S.A = 5117.84 Sq mm.
hexagon S.A = 5151.84 sq mm.
Threaded S.A = 5185.58 sq mm.
HEAT FLUX = q/A=(heat flow)/(surface area)=W/m2
Thermal gradient T = T/x
Cutting tool temperature = 973K
Atmosphere temperature = 500C = 327K
Thermal conductivity = 26 W/mk
Heat flow = Q =KAT

K = thermal conductivity w/mk

Q = rate of heat flow watts

The above image shows meshed model

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International Journal of Research and Innovation (IJRI)

The above imageshows temperature

The above imageshows total heat flux

The above imageshows thermal error

The above image shows stress

MODEL ANALYSIS OF STRAIGHT CYLINDRICAL

The above image shows total deformation mode 1

COUPLED FIELD ANALYSIS OF TAPERED CYLINDRICAL

The above image shows total deformation

The above imageshows temperature

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International Journal of Research and Innovation (IJRI)

COUPLED FIELD ANALYSIS OF STRAIGHT SLOT

The above imageshows total heat flux

MODEL ANALYSIS OF TAPERED CYLINDRICAL

The above imageshows temperature

The above imageshows total heat flux

The above image shows total deformation mode 1

COUPLED FIELD ANALYSIS OF HEXAGONAL SHAPE

COUPLED FIELD ANALYSIS OF THREAD CYLINDRICAL

The above imageshows temperature

The above imageshows total heat flux

The above imageshows temperature

The above imageshows total heat flux

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International Journal of Research and Innovation (IJRI)

GRAPHS AND RESULT TABLES

The above graph shows Total heat flux

The above graph shows Stress

The above graph shows Total deformation

COUPLED FIELD ANALYSIS
STRAIGHT
CYLINDRICAL

TAPERED
CYLINDRICAL

THREAD
CYLINDRICAL

S T R A I G H T HEXAGONAL
SLOT
SHAPE

OCTAGON SHAPE

Temperature

983.69

1059.3

1003.2

1013.2

1001.7

1001.4

Total heat
flux

39.509

51.602

208.59

114.45

39.42

43.291

Thermal error

4.33E+6

1.16E+7

2.70E+7

5.92E+6

1.55E+7

7.85E+6

Total deformation

0.192

0.193

0.195

0.190

0.191

0.190

Stress

3068.6

3452.1

20441

5160.3

3016.4

2999.9

Strain

0.043

0.041

0.120

0.044

0.043

0.043

Model analysis
Total
deformation
mode 1HZ

6973.9

6921.8

6564.6

6832.6

6974

7041.2

Total
deformation
mode 2 HZ

7089.7

7016.8

6867.2

6936.8

7087.7

7146.8

Total
deformation
mode 3 HZ

10745

10593

10433

10409

10629

10959

Total
deformation
mode 4 HZ

16532

16391

15308

15821

16516

16913

Total
deformation
mode 5 HZ

17116

16818

16086

16311

17058

17452

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International Journal of Research and Innovation (IJRI)

REFERENCES

AUTHOR

1.Mechanical properties of the friction stir welded dissimilar aluminium alloy joints international journal of mechanical and production engineering,
2.Friction stir welding of al 6061 alloy
3.Friction stir welds (fsw) of aluminium alloy aw6082-t6
4.Analysis of fsw welds made of aluminium alloy aw6082-t6
Archives of materials science and engineering
5. Design and development of fixture for friction stir welding
Innovative systems design and engineering

G. Ragni,
Research Scholar,
Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India

6.Friction stir welding of austenitic stainless steels

7.An analysis to optimize the process parameters of friction stir
welded low alloy steel plates international journal of engineering,
science and technology
8.Friction stir welding process and its variables international
journal of emerging technology and advanced engineering
9.Analysis and design of friction stir welding
10.Effect of friction stir welding parameters (rotation and transverse) speed on the transient temperature distribution in friction
stir welding of aa 7020-t53 arpn journal of engineering and applied sciences

S.V.S Rama Krishnam Raju,

Professor, Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India

11.Effect of tool geometries on thermal history of fsw of a1100

sponsored by the american welding society and the welding research council

G Nagendra Krishna,
Assistant professor,Department of Mechanical Enineering,
Hyderabad Institute of Technology and Management,
Hyderabad, India

Godi Subba Rao,

Professor, Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India

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