International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 3 | March-2017
p-ISSN: 2395-0072
www.irjet.net
Design and Experimental study of Friction stir welding of AA6061-T6 Alloy for optimization of welding parameters by using Lathe Machine Piyush Patel1, Sachin Patel2, Hiren Shah3 1,2,3Assistant
Professor, Mechanical Engineering Department, C G Patel Institute of Technology, Uka Tarsadia University, Bardoli, Surat, India
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Abstract - Friction stir welding is a new solid state
Frictional heat is generated between the wear resistant welding components and the work pieces. This heat, along with that generated by the mechanical mixing process and the adiabatic heat within the material, cause the stirred materials to soften without melting. FSW is actually performed in different steps as shown in figure 1. The probe primary function is to mix the material under the tool shoulder, which can be enhanced by threads. First, the probe is plunged into the joint formed by the two sheets to be welded, until the shoulder gets in contact. As the tool rotates at a high velocity, the sheets are heated up by plastic deformation and friction. As the pin is moved forward, a special profile on its leading face forces plasticized material to the rear where clamping force assists in a forged consolidation of the weld. This process of the tool traversing along the weld line in a plasticized tubular shaft of metal results in severe solid state deformation involving dynamic recrystallization of the base material. Figure 1 shows process of tool traversing along the weld line. [1], [2]
welding process for joining metallic alloys and it is useful in serve industries for joining aluminium, magnesium and copper alloys. The various parameter such as rotational speed, transverse speed and tool tilt angle play important roles in FSW process and quality weld. The aim of this study is to know the relation between the effects of different transvers speed and tool profile on the weld quality of AA6061-T6 aluminium. The geometry of the pin tool along with the process parameters plays an important role in dictating the path that the material takes. The tool geometry was carefully chosen and fabricated to have a nearly flat welded interface pin profile. In this work, an attempt has been made to analyze the effect of various tool profiles on mechanical properties of aluminium alloy. Various tool profiles have been used to fabricate joints by using varying thickness work piece of Aluminium alloy. Numerical techniques particularly, the finite element method for the simulation of FSW for thermal, mechanical and thermo-mechanical modelling has been investigated. The current studies also aim to understand mechanical properties during the FSW. Key Words: Friction Stir Welding, Transient Thermal Analysis, Al6061, Process parameter, Tool Profile
1.INTRODUCTION (a)
Friction Stir Welding process is relatively a new joining process that is presently attracting considerable interest. Since the joint can be obtained below the melting temperature, this method is suitable for joining a number of materials those are extremely difficult to be welded by conventional fusion techniques. The process is solid state in nature and relies on the localized forging of the weld zone to produce the joint. A constantly rotated non consumable cylindrical tool with a profiled probe is transversely fed at a constant rate into a butt joint between two clamped pieces of butted material. The probe is slightly shorter than the weld depth required, with the tool shoulder riding a top the work surface.
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