Fabrication of FSW Tool Pins Through Turning of H13 Tool Steel: A Comparative Analysis for Residual Stresses

Abstract

In the present research, measurement of residual stress induced during turning and threading operations for the fabrication of two types of pin profiled friction stir processing/welding (FSP/FSW) tools, i.e. cylindrical profiled pin tool and cylindrical threaded profiled pin tool, is being dealt with. Workpiece was chosen to be H13 tool steel with a diameter of 22[Formula: see text]mm and 110[Formula: see text]mm length. Turning and threading was done on CNC machine tools using CNMG 12404-THM uncoated tungsten carbide cutting tool. For residual stress measurement of the workpieces, an XRD-based Pulsetec[Formula: see text]-X360n portable residual stress analyzer setup was used. The experimental results show that the cylindrical pin profile tool had a compressive residual stress of [Formula: see text][Formula: see text]MPa and compressive residual shear stress of [Formula: see text][Formula: see text]MPa, while the cylindrical threaded pin profile tool had a compressive residual stress of [Formula: see text][Formula: see text]MPa (51.8% more) and compressive residual shear stress of [Formula: see text][Formula: see text]MPa (40% less). It has been concluded that due to threading operation on the cylindrical threaded pin profile, the value of residual stress is more in it, and since the stress is compressive in nature, it would have a better positive impact while doing FSP/FSW than that of the cylindrical profiled pin tool.

Proposal for the identification of residual stresses after turning and hardening of bearing steel

“…The paper (Elsheikh et al, 2021) provides a detailed review on residual stresses induced by turning on machined components. In this review, the authors explore the different methods of measuring residual stress, the effects of cutting parameters such as cutting speed, depth of cut, and feed rate, the configuration of cutting tools, cooling conditions and wear conditions, as well as the creation of residual stress in hard-tomachine materials (Outeiro et al, 2008;Peng et al, 2020;Biasibetti et al, 2021;Butola et al, 2021;Zheng et al, 2022).…”

Mechanical and Electrical Characterization of Friction Stir Welded Copper and Aluminum Alloys

“…The material is mixed as the tool rotates, resulting in material migration from the front to the back of the tool pin [7]. During the friction stir welding process, the threaded pin profile results in increased levels of residual strain and stress [8]. The microstructures generated during the welding process, for example, had a considerable impact on the hardness and tensile strength of the precipitated phases in the nugget zone [9].…”