Design and development of force and torque measurement setup for real time monitoring of friction stir welding process

Das, Babulal; Pal, Sukhomay; Bag, Swarup

doi:10.1016/j.measurement.2017.02.034

Cited by 35 publications

(7 citation statements)

References 24 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Asymmetric flow occurs around the tool due to the interaction between lateral and axial forces [75,200]. The force and torque measurement of the tool is essential for three reasons: large torque relates to more power for the process, enhancement in tool wear and deformation with an increase in load, and tool wear leads to a fault in the weld and deterioration in joint properties [201,202]. As per the literature, there are two positions wherein sensors were placed: i. on top of the workbench and ii.…”

Section: Force Measurementmentioning

confidence: 99%

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

Prabhakar,

Korgal,

Shettigar

et al. 2023

JMMP

View full text Add to dashboard Cite

This review reports on the influencing parameters on the joining parts quality of tools and techniques applied for conducting process analysis and optimizing the friction stir welding process (FSW). The important FSW parameters affecting the joint quality are the rotational speed, tilt angle, traverse speed, axial force, and tool profile geometry. Data were collected corresponding to different processing materials and their process outcomes were analyzed using different experimental techniques. The optimization techniques were analyzed, highlighting their potential advantages and limitations. Process measurement techniques enable feedback collection during the process using sensors (force, torque, power, and temperature data) integrated with FSW machines. The use of signal processing coupled with artificial intelligence and machine learning algorithms produced better weld quality was discussed.

show abstract

Section: Force Measurementmentioning

confidence: 99%

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

Prabhakar,

Korgal,

Shettigar

et al. 2023

JMMP

View full text Add to dashboard Cite

show abstract

“…In this series, Ahmad et al 40 designed the extended octagonal ring force dynamometer for the measurement of force during FSW. Das et al 41 designed and developed the force and torque (strain gauge based) measurement set up for measuring the Z-Force during FSW. The demonstration of force signal in artificial intelligence is to predict the strength (UTS and YS) (with accuracy) (% prediction error 0.48% and 0.72%) of material using the support vector regression model.…”

Section: Introductionmentioning

confidence: 99%

Prediction of heat generation effect on force torque and mechanical properties at varying tool rotational speed in friction stir welding using Artificial Neural Network

Kumar

Triveni

Katiyar

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

Friction stir welding (FSW) has played a significant role in joining aerospace alloys. During this process, the tool rotational (TRS) speed has been found to significantly affect heat generation compared to other parameters. Therefore, the study has investigated the effect of heat generation on force-torque and mechanical properties at different tool rotational speeds (TRS) in the FSW process through experimentation followed by Artificial Neural Network (ANN) technique. Further, the influence of different TRS ranging between 600 and 1800 rpm with an increment of 400 rpm on considered responses; namely thermal weld cycle, microstructure, and grain distribution in nugget zone (NZ) for 2050-T84 Al-Cu-Li alloy plates, welded using FSW were also investigated. It is observed that the vertically downward force (Z-force), longitudinal force (X-force), and spindle torque (Sp. T) decrease with increasing TRS. It is also observed an increasing (up to 1400 rpm) and then decreasing trend for tensile strength and hardness of welded samples. Moreover, the generation of frictional heat and grain size in NZ is increased with increasing TRS from 600 to 1800 rpm. However, the scanning electron microscope (SEM) micrographs of all-welded samples revealed a ductile mode of tensile fracture. Furthermore, the obtained experimental results were validated using the ANN technique. A quite better agreement has been established among the predicted outcomes from ANN with experimental results.

show abstract

“…Papahn et al designed and developed a novel fixture for simultaneously measuring axial and transverse forces during friction stir welding process [18]. There are still many researchers who have carried out this measurement work, making significant contributions to understanding the impact of process parameters on the microstructure and mechanical properties of the joint [19][20][21][22][23][24][25][26][27].…”

Section: Introductionmentioning

confidence: 99%

A Study on Microstructure and Mechanical Properties of Micro Friction Stir Welded Ultra-Thin Al-1060 Sheets by the Shoulderless Tool

Zhang

Wang

Jin

et al. 2019

Metals

View full text Add to dashboard Cite

The welding tool is the key of micro friction stir welding (μFSW), which affects the heat input and the plastic forming of weld metal. In this paper, 0.8-mm-thick ultra-thin 1060-H24 aluminum sheets μFSW butt joints were used to compare and analyze the influence of the conventional tool and shoulderless tool on weld shaping, microstructure and mechanical properties. Besides, by measuring the axial force, transverse force and weld temperature in μFSW process, the influence of these two different tools on the heat input and metal flow mechanism of the weld were analyzed. The results show that the weld generated by the shoulderless tool has narrower width, less heat input and metal involved in plastic forming resulting in smaller HAZ (heat affected zone). The hardness of NZ (nugget zone) is obviously increased compared with that of the base metal. The highest tensile strength can reach 108.6 MPa, accounting for 78.6% of the base metal and 117.3% of the joint by the conventional tool. But the welding defects have to be overcome for industrial application of the shoulderless tool.

show abstract

Design and development of force and torque measurement setup for real time monitoring of friction stir welding process

Cited by 35 publications

References 24 publications

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

Prediction of heat generation effect on force torque and mechanical properties at varying tool rotational speed in friction stir welding using Artificial Neural Network

A Study on Microstructure and Mechanical Properties of Micro Friction Stir Welded Ultra-Thin Al-1060 Sheets by the Shoulderless Tool

Contact Info

Product

Resources

About