FABRICATION OF WORKING MODEL OF FRICTION STIR WELDING AND DESIGN OF PROBE AND ANALYSIS

8/12/2019 FABRICATION OF WORKING MODEL OF FRICTION STIR WELDING AND DESIGN OF PROBE AND ANALYSIS

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Design of frictionwelding

Probe and Analysis

GUIDE:- D.SHIVA KUMAR SIR.

BY, Y.R.Sai Kiran (2451-10-73-11!"

#.Var$n (2451-10-73-10!"

D.Sri%an&'(2451-10-73-0!"

M.Sai #raa)(2451-10-73-07"

1


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PROJECT REPORT

ON

FABRICATION OF WORIN! "ODE# OF FRICTION $TIR

WE#DIN! AND DE$I!N OF PROBE AND ANA#%$I$

$&b'itted in (artial f&lfill'ent of t)e re*&ire'ent

For t)e award of t)e degree of

Bac)elor of Engineering

In

"ec)anical Engineering

By

%+R+$ai iran &'ar Reddy ,-./0102134510067

P+ 8ar&n ,-./0102134510267

D+$ri'ant) ,-./0102134512657

"+$ai Prasad ,-./0102134512357

9nder t)e estee'ed g&idance of

"r+D+$)i:a &'ar Dr+"+"ad)a:i

Associate Professor ;ead of De(art'ent

"ec)anical De(art'ent "ec)anical De(art'ent

De(art'ent of "ec)anical Engineering

"8$R Engineering College

Afflicted to Os'ania 9ni:ersity

Naderg&l< ;yderabad

-2021-20.

2


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Maturi Venkata Subba Rao Engineering College

(Sponsored by Matrusri Education Society) Estd. 1981

Ailiated to !s"ania #ni$ersity % Recognised by A&C'E

adergul(.!.)* +yderabad , -1 -1. Saroornagar Mandal. R.R./t. A..

'el0 912831-2433856* 433859 'elea70

"EC;ANICA# DEPART"ENT

CERTIFICATE

*'i i &+ r&i/ &'a& &' r+& r+r& n&i&) ABRIA*I6 6 86RKIG

M6DE9 6 RI*I6 S*IR 8E9DIG AD DESIG 6 #R6BE AD

AA9YSIS i a ;+nai) r+r) + &' r + Ba'+r + En>inrin>.

NA"E OF T;E $T9DENT RO## NO

Y.R.Sai Kiran K$%ar R))/ 2451-10-73-11!

#.Var$n 2451-10-73-10!

D.Sri%an&' 2451-10-73-0!

M.Sai #raa) 2451-10-73-07

Internal Guide Head of Department

"r+D+$)i:a &'ar Dr+"+"ad)a:i

Associate Professor Professor

"ec)anical De(art'ent "ec)anical De(art'ent

3


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ACNOW#ED!E"ENT

8 &a= &'i ++r&$ni&/ &+ r%%;r an) a=n+ &' ++ra&i+n, >++)


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AB$TRACT

In +r)r &+ i%r+@ %a&ria +< ;'a@i+r )$rin> ri&i+n &ir an) a@+i) r++& a &' +< @+i&/ + %a&ria nar &'

;+&&+% + &'


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C;APTER .@ !EO"ETRIC "ODE##IN! AND ANA#%$I$ OF F$W PROBE

.+0 Introd&ction

.+- Different "odels of Probe

.+4 !eo'etrical 'odeling

.+. Analysis on "aterial flow be)a:ior of Probe

.+0+0 "es) !eneration

.+.+- "aterial Para'eters

.+.+4 Bo&ndry Conditions

C;APTER /@ RE$9#T$ CONC#9$ION$ AND F9T9RE PRO$PECT$

APPENDI?

7


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C;APTER 0

INTROD9CTION

8


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0+07 INTROD9CTION@1

6@r &' /ar &'r 'a ;n %an/ a&&%& &+ )ri; &' 'n+%na + ri&i+n.

I& 'a ;n a r+;% +r %an=in) &'r+$>'+$& &' a>. A %an ;a% %+r in@n&i@, $ra

an) %a&ria ra 'a@ ;n &' rini %&'+) + ain> a ;+$n)ar/ a/r ;&nra&i+n + %&a an) %a&ria &'a& 'a@ inra) ra.

Ma>naa& 'a ;n in &' +rr+n& + a%+& a &' n +r in +% a, %$&i a/r + +& an) 'ar) %&a ar )+i&) an) &'n )i$)

;+&' in&+ an) +n &+ + &' ;a %&a.

*' @r->r+ a + &'n++>ia a)@an%n& r%ain a ;$r+ + in)$&ri. 6n $' inn+@a&i@ r+ &'a& +n&in$ &+ %a= i& %ar=

& ar+ a @ari&/ + &+r i ri&i+n . ri&i+n i a r+@n an) +&-&i@

%&'+) + +inin> i%iar +r 'i>'/ )ii%iar %a&ria &'a& 'a r+@n &+ ; @r/ +$ar in

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E$r+ an) Aia, ;$& i ar>/ $n=n+


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Fig @ 0+0+0< Friction welding of Two rods

0+-7 Proect O:er:iew@1

*' #r+& a;ria&i+n + %+) + S8 an) Di>n + #r+; an)

ana/i i@ $ an +@r@i< + + ri&i+n-&ir %a'in an) &'

i%+r&an + #r+; in S8 an) @ari+$ ara%a&r &'a& & &' &i@ + &'

ri&i+n-&ir r+;.

I& a+ >i@ $ in+r%a&i+n a;+$& Ma&ria +< r+r&i ana/i


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HA#*ER 2

*HE6RY 6 S8 AD #R6BE

-+07 $O#ID $TATE WE#DIN!@112


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S+i)-&a& rr &+ +inin> r+ in r+ a

3" Di$i+n 8)in>

4" E?+i+n 8)in>

5" U&ra+ni 8)in>

" ri&i+n 8)in>

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-+-+07 Forge Welding:-

+r> i a r+ in ) &+>&'r ;/ 'a%%r +r +&'r %an. +ni)ra;

=i &'n++>/ '+


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-+-+-7 Cold Roll Welding@1

+) r+ i a +i)-&a& r+ a+%i') ;/ a/in> 'i>'

r$r ;/ %an + r+ ;& $ra a& r++% &%ra&$r. M&a &+ ;

+) an) i@r an ; ra)i/ +)-

&ain & &+ %i) & +r +rr+i+n ri&an, %a=in> ;i%&ai &ri +r %a$rin>

&%ra&$r, an) r+)$in> an)


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Di$i+n 8)in> i a +i)-&a& r+ &'a& r$& r+% &' aia&i+n

+ 'a& an) r$r, $$a/ in a +n&r+) a&%+'r, +in& + &'

%&a, an) a&i )+r%a&i+n a& &' $ra i +n/ %ini%a.

Aia&i+n + )i$i+n in$) &' +inin> + 'i>'-&rn>&' an) rra&+r/

%&a in &' ar+a an) n$ar in)$&ri. *' r+ i $) &+ +in ;+&' i%iar an)

)ii%iar %&a, an) in &' a&&r a a ir a/r + a )irn& %&a i +&n an)


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Fig@ -+0+.< Diff&sion Welding

-+-+.7 E(losion Welding@1

E?+i+n 8)in> i a +i)-&a& r+ in a;+@ &' $r a&, a) &' /r a&. A ;$r

a/r (+r ?a%, r$;;r +r a&i" i +&n $) ;&


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)&+na&i+n i ini&ia&), &' ?+i@ 'ar> r+a>a& r+% +n n) + &' /r a& &+ &'

+&'r. *' r$&in> 'i>'-r$r C+n r+ &' /r a& &+ +i) ri@/ a& 'i>' @+i&/, + i& &a= +n an an>$ar 'a a &' ?+i+n a)@an, a

i$&ra&) in &' =&'.

E?+i+n i +%%+n/ $) &+ ;+n) & ara. Aia&i+n in$) r+)$&i+n +

+rr+i+n-ri&an& '& an) a& &+= +r %a=in> r+in> $i%n& in &' '%ia an)

&r+$% in)$&ri. *' &r% ?+i+n a))in> i $) in &'i +n&?&. + ir %&a i $)

in ?+i+n , an) n+ ?&rna 'a& i ai).

-+-+/7 9ltraso&nd Welding@1

M+)ra& r$r i ai) ;& $ra. *' +%;ina&i+n

+ n+r%a an) @i;ra&+r/ +r r$& in 'ar &r &'a& r%+@ $ra i% an) a'i@

a&+%i ;+n)in> + &' $ra+

Fig@ -+0+5< 9ltra1$o&nd Welding

-+47 Friction Welding@1

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ri&i+n i a +i)-&a& r+ in ia ;+n).

*' a?ia +%ri+n +r $& &' ar&, an) &' %a&ria )ia) r+)$ a a'.

*' a' %$& ; $;$n&/ &ri%%) &+ r+@i) a %++&' $ra in &' i+n. + ir

%&a, $?, +r 'i)in> >a ar r$ir).

Ma'in $) +r ri&i+n 'a@ &' aaran + an n>in a&'. *'/ r$ir

a + an a?ia +r ;& ar&.

8i&' i& '+r& / &i%, &' r+ i $i&a; +r %a r+)$&i+n. I& i ai) in &'

+ @ari+$ 'a& an) &$;$ar ar& + i%iar +r )ii%iar %&a. 6n &/ia aia&i+n

+ ri&i+n i &+ +a %)i$%-ar;+n & 'an= &+ ar;i) &i in r+)$in> &


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Fig@ -+4+0< Friction Welding Process

-+.7Classification of Friction Welding:-

Dirn& */ + ri&i+n 8)in> Ma'in

3" 9inar ri&i+n

4" ri&i+n $rain>

5" 9inar rir+a&in> ri&i+n 20


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" 6r;i&a ri&i+n

7" An>$ar rir+a&in> ri&i+n .

!" Ra)ia ri&i+n

-+.+07 Rotary Friction Welding@1

R+&ar/ ri&i+n ;ar i r+&a&) ;/ a %+&+r /

r+, %+r +&n a) inr&ia . *' r+&a&in> +%+nn& i a&&a') &+ a /ain& &' &a&i+nar/

+%+nn&. *' r$&an& ;ra=in> a&i+n >nra& &' r$ir) 'a& +r . S+%&i%

a))i&i+na r$r i r+@i)) &+ +%& &' ri&i+n an ; aii) in&+ &+ri:-1" +n&in$+$ )ri@ ri&i+n

2" Inr&ia ri&i+n

1" Contin&o&s Dri:e Friction Welding:-

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-7 Inertia Friction Welding@1

Inr&ia ri&i+n 8)in> i a @aria&i+n + ri&i+n in /. *' )ri@ %+&+r i )in>a>) an) &' &'r ;/ &'

ri&i+n +r. *'i a$ &' a/in> $ra &+ r$; &+>&'r $n)r r$r.

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*' =in&i nr>/ &+r) in &' r+&a&in> / +r i %ain&ain) +r a r)&r%in)

&i% a&r r+&a&i+n a.

6n + &'


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-+.+-7 $(in Friction Welding@1

Sin /&% +ni& + & &' %a&ria &+ ; i@n '&. *' i i &'n $n $ &+ a 'i>' ra& +

r+&a&i+n &+ &+r &' r$ir) nr>/ in &' /&'r $n)r r$r. *' +r i =& +n &' i a&r &'

innin> &+ &+ a+< &' 'a. In &' +i)

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ri&i+n 'a, 'a& i >nra&) a a r$& + &' ri&i+n ;&nra&) i

)n)n& +n &' ai) &an>n&ia @+i&/ an) &' r$r. In &' +n) 'a, a &'in %+&n

+/%r a/r i +r%) r+nra&i+n. In &'i &a> 'a&

i >nra&) ;/ @i+$ )iia&i+n. A& ir& +n/ a &'in %+&n a/r ?i& an) +n$n&/ &'

'ar ra& an) @i+$ 'a&in> +n&ri;$&i+n ar ar>. A &' &'i=n + &' %+&n a/r

inra &' )>r + @i+$ 'a&in> )ra.

*'ra&r, &' %&in> ra& $a &' +$&a &$r;in.

En&ia/, i& i a n+n-%&in> $i+n r+ r+)$in> 'i>' in&>ri&/ . *' ) ar %$' +nra, &'a& ar& + an/ 'a an ; +in), a ++) &+ ar&


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%&in> +in&. An+&'r a)@an&a> i &'a& in %+& in&an $ai&/ + +in& i ;&&r &'an &'a&

+;&ain) $in> r+&a&in> &'ni$.

9inar ri&i+n , (+ na%) ;a$ &' ra&i@ %+&i+n i inar ar+ &'

in&ra, ra&'r &'an r+&ar/", i ara)/ $) &+ +in ;a) +n&+ )i in &' ar+ n>in in)$&r/.

9+in ar&. A &' ar& &+

; nra& ri&i+na 'a& in &' i%%)ia& r>i+n a;+$& &' &i%

+ &' +r)r + a < +n), an) &' )ir& 'a& in$& a& &' i@ ri &+

ra&i@/ %a 'a& a&) C+n.

*'i, ;/ $)ii+$ &i+n + +%+nn& >+%&r/, &'i a+ i%i& r+ in)$)

)i&+r&i+n. *+ &'i )a&, ri+$ i&& rar' 'a ;n )+n in &' ara + 98. I& i >nra/

a&) &'a& ri&i+n an ; ara&) in&+ (i" a )r/ ri&i+n &a>, ++' &a)/ &a& 98.

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Fig@ -+.+0< #inear Friction Welding

-+.+.7 Friction s&rfacing@1

ri&i+n S$rain> i a r+ )ri@) r+% ri&i+n +n %'&r+) )ia%&r an) +a&in> %a&ria".

*' r$&in> +%+i& %a&ria i ra&) &+ r+@i) &' 'ara&ri&i

)%an)) ;/ an/ >i@n aia&i+n.D$rin> &' +a&in> r+, &' ai) a/r + %&a

ra' a &%ra&$r nar &' %&in> +in& i &'$ &' r+)$& + a '+& +r>in> a&i+n, a ++) &+ &' a&in>

%'ani% in'rn& in an) ra/in> r+.

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*'i i%+r&an& )irn %an &'a& %an/ + &' )& +%%+n/

a+ia&) %a&ria i ai) &+ a $;&ra&. A r+) +%+) + &'

+a&in> %a&ria (a) a %'&r+)" i r+&a&) $n)r r$r, >nra&in> a a&ii) a/r in

&' r+) a& &' in&ra a $;&ra& ar+ &' a + &' r+&a&in>

r+) a a&ii) a/r i )+i&) ;&


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A %in+r %+)iia&i+n i an>$ar ri&i+n , .

Fig@ -+.+4< #inear Reci(rocating Friction Welding Process

-+.+57 Orbital friction welding@1

6r;i&a ri&i+n i i%iar &+ in , ;$& $ a %+r +%? %a'in &+

r+)$ an +r;i&a %+&i+n in


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Fig@ -+.+/< Friction1$tir Welding Process

S+% + &' r+ a)@an&a> ar >i@n in &' ++ i&:

1.S8 i nr>/ iin&.

2.S8 r$ir %ini%a, i an/, +n$%a;.

3.S8 r+)$ )ira; %ir+&r$&$r in &' &+>&'r )irn& %a&ria,

+n + '

$ai&/


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+r n+n-'+%+>n+$ +in& in@+@in> %a&ria 'a@in> $i& )irn& '%ia , %'ania an)

&'r%a r+r&i. *' r+ i $i&a; +r a$&+%a&i+n an) a)+&a; +r r+;+& $. 6&'r

a)@an&a> a ++rain '+&- +& a@in>

-100J B+n) + $ r+ &i+n

- Hi>' r+)$&i+n ra&

-A$&+%a&i ra&a;ii&/

-S&r+n>r &'an arn& %a&ria, i

-n@ir+n%n&a/ rin)/ r+ %ini%iC nr>/ +n$%&i+n an) >nra& n+ %+=, >a

+r &' $a +r >ra&r &'an &'a& + arn& %a&ria

-+in 'i>'/ )ii%iar %&a +%;ina&i+n &+ +&i%iC /+$r r+)$& $ai&/ an) r+r&i-a@ a;+r, %a&ria an) +ra&i+n &'r+$>' nar n& iC )i>n

-+in +&/, i>'&r +r &$;$ar %a&ria &+ ?ni@ %a&ria.

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-+37 Disad:antages of friction welding@1

*' )ia)@an&a> + ri&i+n ar &'a& n+& @r/ +ni>$ra&i+n i ai;, &'a& a

%a'in + $iin& + + &' +%+nn&, a +%ar) &+ &'a& in a' +r ;$&& .

7. *'r i n+ $?, >a, ir %&a +r a> rn& &+ a$ i%r&i+n in &) $ ar, ;$& n+& i%i&) &+: *++

?&ni+n, &++ ;an=, ;a;a ;a&, >+ $&&r, air /in)r, %$ni&i+n, a&nr, +i i an)

, ;i/ ar&, %)ia $i%n&, %arin $i%n&, &ria $i%n&,

'+&+>ra'i an) +$n) $i%n&.

34


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Fig@ -+6+0< Flange

-+ Aeros(ace@

$ &rn>&' inr&ia


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4+ ;ydra&lic@

H/)ra$i /in)r an) @a@ ar ri% an)i)a& +r inr&ia . *' /in)r

an ; +%&/ %a'in) an) &' a an ; $ar 'a, &' /in)r an ; r

i + %a&ria &+ r)$ +& an) %a'in &i%. *'i r+ a+ n) i& &+ &' i&+n an)

'a& &' ri>'& %&a in &' ri>'& a. Uin> a &r+n>r

%a&ria +r &' &% an) a 'a& &+ran& %a&ria +r &' 'a). 6&'r aia&i+n in$),

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)irn&ia ++, )ri@ 'a&, a?, r+n& &' +%ani $ ;i-%&a ,


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>a &+ %&a a an) n$%r+$ +&'r ri&ia r+)$&. *'i &'n++>/ i ;in> ?an))

)ai/ in +$r aii&/. ri&i+n ' &+ +in a + ar& 'a,

%a&ria, an) ri$&$ra %a'inr/, a$&+%+&i@ ar&, +i i) i,


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3+ Drill rods@

Man$a&$r) in '+$, +r& E$r+)ri an &+ r+@i) D*H ri&i+n 8)) Dri *$;

an) R+&ar/ Driin> ri&i+n 8)) Dri R+)


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Fig@ -+6+3< 9ni:ersal Joint %oe

Fig@ -+6+6< Friction Welding Prod&cts

-+7 &ality and en:iron'ental as(ects@1

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*+)a/, an/ n< in)$&ria r+ n) &+ ; &'+r+$>'/ a) r>ar)in> i&

i%a& +n &' n@ir+n%n&. ar$ +ni)ra&i+n + HSE (Ha&', Sa&/ an) En@ir+n%n&"

i$ a& &' in n/ +%%+n +r %an$a&$rr &+ %+ni&+r a r+)$& n@ir+n%n&a

i%a& &'r+$>'+$& i& i /.

-++07 #ess weld1sea' (re(aration@1

B$&&, +@ra an) ;in) $ra&i+n, >ra&r a $/ +r an&

in@&%n& $' a r$r &an=, i i&&in> an) >a r>$a&+r, a +n> a i& i ai) &+ + &%ra&$r %a&ria $' a a$%ini$%. + n) +r +n$%a;, i%ina&in> &' n)

+r &'ir &+ra> an) &ran+r& ini) &' r+)$&i+n ara, an) a@+i)in> &' n) +r &'ir

r+)$&i+n


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nr>/. $r&'r%+r, &' $ +r $ar-' &'i i +&n i>n+r). D$ &+ i& &ri in) )ri@ an) '/)ra$i $ni& +r

a?ia r$r, an S8 $ni& >nra& +ni&n&/ n+i, +%ara; &+ a &an)ar) %iin>

%a'in

-++.7 Energy sa:ing F$W (rocess@1

8'n +ni)rin> nr>/ +n$%&i+n, &'r a&+r %$& ; a): '+< %$'

nr>/ i r$ir) &+ r+r% &' / i r$ir) +r +& &ra&%n& (>rin)in> an)

anin>". Gnra/, S8 )%an) nr>/ in$& &+ &' / in$& )n) +n &' iC + &' $i%n& ;in> $) an) &'

&'i=n + &' +in&, )n)in> +n -a +r %$&ia i $). S8 i

a a, +rin> &' >ra&& nr>/ a@in> a& 'i>'r a&i@ i%a& +n &' n an)

)i@r


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0/ Ton "ac)ine to Weld Drills< Rea'ers and IC Engine 8al:es

43


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0/ Ton "ac)ine for welding ale )o&sing of Tr&cs

5 Ton 8ertical friction Welding 'ac)ine to weld IC Engine :al:e

44


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-+027 Weldable "aterial Co'binations@1

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*'i 'ar& '+


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C;APTER 4

ABRIA*I6 6 RI*I6

S*IR 8E9DIG

4+07 Introd&ction@1

47


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ri&i+n S&ir 8)in> (S8"

In&i&$&", an) &' ir& a&n& aia&i+n ) in&+ &'

+in& ara ;& +r) aar&. ri&i+na 'a& ;& &' )> + &'

&++ in, i +r>) &'r+$>' in&i%a& +n&a& >a. Ma&ria &'i=n ran>in> r+% 0.5 &+ 5 %% an ; S8 &+ ; ai) &+ a ;r+a) ran> + %a&ria.

*+ a$r 'i>' ra&a;ii&/ an) $ai&/ $r

3 ar/ )%+n&ra& &' i%r+@) r+r%an + S8 +%ar) &+ a MIG-


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Fig@ 4+0+0< Friction1$tir Welding Process

4+-7 Co'(onents of F$W "odel@1 ,!eo'etrical 'odels7

*' Main +%+nn& + 8+r=in> M+) + ri&i+n-S&ir 8)in> &'a& n) in

S+i) 8+r= Ar:

1" #r+;

2" Si)r

3" M+&+r

4" Vr&ia S$+r&

5" 9+n> Sr< G$i) '&-/in)ria-*ar)-*'ra))-*++

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2" S&rai>'&-/in)ria-*ar)-*++

3" S&rai>'&-/in)ria-*'ra))-*++

4" S&rai>'&-/in)ria-*++

5" S&rai>'&-Sa$r-*++

07 $traig)t1Cylindrical1Ta(ered1T)readed1Tool@1

*'i *++ i + /in)ria 'a


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*'i i a% a a;+@ ;$& i& 'a n+ r< &'ra) +n &' *ar) ar& + &' &++.

*'i &++ i $) +r %++&' %a&ria $' a a$%ini$% &.

47 $traig)t1Cylindrical1T)readed1Tool@1

*'i &++ 'a a /in)ria r+; a& &' ;+&&+% + &' &%


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*'i &++ i a% a a;+@ ;$& &' ;+&&+% /in)ria r+; ar& i n+& *'ra)).

*'i &++ i $) +r +& %a&ria.

/7 $traig)t1$*a&re1Tool@1

*'i &++ 'a a $ar 'a) r+; a& &' ;+&&+% + &' &%. *'i &++ i $) +r

$r+ + 'i>' )$ra; an) 'a@/ %a&ria.

4+-+-7 $lider@1

52


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*' Si)r i &' %ain $+r&in> ar& + &' %a'in +r %+) i@ $+r& +r

&' -'a) &r$&$r in +$r %+). *' Si)r ;ar a &' +a) + %+&+r, -

'a an) &++.

Di'ensions:-

9n>&'----- 2000%%

Bra)&'-----00%%

Hi>'&------- 125%%

Si)r ar&----- 2000N150%% in %i))

Ga---------- 50%%

4+-+47 "otor@1

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*' %+&+r i &' %ain +%+nn& + ri&i+n Ha& ;& &' 9+n> Sr< >$i) &' $+r& r+) +r &'

-'a &r$&$r.

4+-+/7 #ong $crew !&ide Wit) ;andle@1

54


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*'i i &' %ain +%+nn& + S8 /in)ria r+)


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Fig@ 4+0+5< F$W "odel

58


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4+.7 Proect Pict&res@1

Fig@ 4+0+4< F$W "odel

59


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Fig@ 4+0+/< F$W Front 8iew

60


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C;APTER .

!eo'etric "odelling

And Analysis Of F$W Probe61


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.+07 Introd&ction@1

8)in> &++ )i>n i ri&ia in S8. 6&i%iin> &++ >+%&r/ &+ r+)$ %+r

'a& +r a'i@ %+r iin& &irrin> +r & an) %i?in>

+ &' +?i) a/r an) %+r iin& 'a& >nra&i+n, /i)in> 'i>'r ) an), +

+$r, n'an) $ai&/. *' i%& &++ an ; %a'in) r+% an M20 ;+& ' a& @r/ +< ). H+'

'ar)n a& @a&) &%ra&$r, an) '+$) r&ain &'i 'ar)n +r an ?&n)) ri+). *'

+%;ina&i+n + &++ %a&ria an) ;a %a&ria i &'r+r a i) ;/ &' +& &' S8 r+ i )i$) ;/ $in> &' +&++), an) a %a&ria &'i=n i inra), 'a& a& &' ++%&r/ +&i%ia&i+n, &' +?i)-a/r +$); ;r+=n %+r &i@/. *' n) &+ >nra& %+r ri&i+na 'a& an) ;ra= &' +?i)-a/r

62


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%+r &i@/ 'a ;n a )ri@in> +r in &++ )@+%n& +r i>'&-%&a. In i>$r ;++%&ri a&$r, &+

%a&' &' n) + ii aia&i+n. *++ %a&ria +r %i) an) &ain & 'a@ ;n

a))) &+ &' i&. i>$r ;+< i$&ra& +% &an)ar) &++ &ra)%ar=) ;/ *8I (*' 8)in>

In&i&$&". *ri$& MNO 'a r+@n &+ ; a @r/ aa; %$&i$r+ &++ +r a

a$%ini$% a+/.

Fig+.+-+0


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*+ a/ S8 in & +r +&'r 'i>'-&%ra&$r %a&ria, &' )ii$&/ i %ain/

a+ia&)


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D$rin> &' S8 r+, &' %a&ria i in a a&i &a&. *' %a&ria

%$& ; &irr) an) &'n %i?) n+$>' &+ >& a +$n) S8 + &' @i+n& + ;+n), r++& a &' S8 r+, &' &i + &' r+&a&i+na in i ini) &' %a&ria

in +r)r &+ a@+i) +n&a& ;& a& an) &'n &' )a%a> + &' &++

+r ;a=in> a&. Gnra/ a=in>, &' )i&an ;& + $n>in> )&' + &++. *' +n>r )i&an %a/ r$& in

&' aaran + r++& a


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(a" *' +n@n&i+na &++ $) (;" *' &++ $r 1a, &'

)ia%&r + &' '+$)r i 17 %% an) &' +%&r/ +n %a&ria +< @+i&/ an) &'n $>>&) &'a& &' $& >+%&r/

+ &' &++ i &' %+& i%+r&an& a&+r &+ ; )i>n). +r &' &


67/78

.+.+07 "es) !eneration@1

i>$r ;+< '+K, 15.1

8L%K an) 4.45 >L%3, r&i@/. *' RG =- %+) i $) in &'i &$)/ an) &' %a&ria i

$+) &+ ; $) i$i). *' @i+i&/ + *iA4V a+/ i $n'an>) an) &' @a$ i 5.3

%#a.

.+.+47Bo&ndary Conditions@1

D$rin> &' r+ + n$%ria i%$a&i+n, &' a&i %a&ria i +ni)r) a &'

$i),


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)ir&i+n. *' %n& $) &+ rrn& &' r+&a&i+na &++ ar +ni)r) a &' r+&a&i+na S8, &'r rrn&a&i@ +i&i+n ar

+ni)r) nar &' $ra, in &' %i)) +


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)i@i)) in&+ & &' @r&ia )ir&i+n, &' +< @+i&/ an) &' r>i+n

$n)r 'i>' +< @+i&/ ;+&' )ra


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Fig ,.+.+.10b7Flow Field at $ection ,a7 Parallel to Wor Piece

Fig .+.+.10cFlow Field at $ection ,b7

70


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Fig .+.+.10d Flow Field at $ection ,c7

,ii7 Effect of Fl&te !eo'etry on "aterial Flow@1

*' i>$r ;+< '+< %a&ria +< @+i&/ i) ;/ &' +n@n&i+na &++

an) &' &++


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Flow field at section ,b7 by t)e tool wit) t)e )alf1screw (in+

Flow field at section ,c7 by t)e con:entional tool

72


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Flow field at section c by t)e tool wit) t)e )alf1screw (in.

r+% i>$r 4.4.4 (1a &+ 1)", i& i a+ +n$)) &'a& &' $& + &' &++ an>ra&/ inra &' +< V+i&/ + &' %a&ria. *'r+r, &' ra+na; )i>n + &' $&

>+%&r/ i @r/ i%+r&an& &+ &' r+&a&i+na &++ + S8. A&r $i) +


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V1 A1 V2 A2 +n&an&TTT. E (1"

&' +< @+i&/ + &' %a&ria,


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C;APTER /

RESU9*S AD 69USI6S

75


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/+07 Res&lts@1

*' A%;/ + ri&i+n-S&ir 8)in> %+) i )+n an) i i&&) a i)-'a& D %+&+r.

/+-7 F&t&re Pros(ects@1

r+% &'R$& a;+@ S8 %a'in %+) i i& &+ ; ;$i& in&+ $ a %a'in

&'n &' ++ a&+r '+$) ; +ni)r)TT.

1" M+&+r aai&/

2" #r+; &i %a) + 'r+%-&

3" #r+; i&&) &+ Garin> /&% ar) &+ %+&+r

4" Ha-Sr< $& *ar) S'+$) ; r+i + r+; *i +r ;&&r %a&ria-+< *i%in> Gar ;& r& 8).

Concl&sions of Analysis@1

S8 i 'r &+ &a/. *' r+ 'a )%+n&ra&) i& aa;ii&i an) ;n

ar+@) a a n+@ %&'+) +r +inin> a$%ini$% an) +&'r %&a. S8 i +nin> $ &+&a/

n< ara + )ai/. *' r+ i%r+@ ?i&in> &r$&$ra r+r&i an)

a@ &' ra&/ in$n &' %a&ria

76


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+< ;'a@i+$r. *' &++ r++& ain> *'n++>/ an) A)@an) En>inrin>, ri&i+n-S&ir

, V+$% 4, I$ 3, Ari 2003.

3" S8 *'nia Han) ;++= ;/ ESAB.

4" S&$)/ + S8 B/ Ran'an Sa'++, Gra)$a& r+% II* R++r=.

5" Man$a&$rin> En>inrin> an) *'n++>/, Kaa=ian S'%i), L, 2010 'a&r

13

" #in *++ G+%&r/ E& in ri&i+n S&ir 8)in> B/ Q.A. $rin, H.A. R$;i+, Q.A.

S'ni)r, Dar&%n& + M'ania En>inrin>, Miiii S&a& Uni@ri&/.

7" ri&i+n S&ir 8)in>L#r+in> *++ Ma&ria an) S&i+n B/ K$)Cana/i 'i&=a

#r+)$&i+n n>inrin>, D'i *'n++>ia Uni@ri&/, In)ia.

!" ri&i+n &ir &++ B/ R. Rai, A. D, H. K. D. H. B'a)'ia an) *. D;R+/.

" $n)a%n&a + M+)rn Man$a&$rin> ,Ma&ria ,#r+ ,an) S/&% ,4&' )i&i+n,

Q6H 8I9EY S6S, I.,2010

10" Var/ Marin+@, Man$a&$rin> *'n++>/, S+i)-&a& 8)in>, 'a&r 12 a> :-

132.

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FABRICATION OF WORKING MODEL OF FRICTION STIR WELDING AND DESIGN OF PROBE AND ANALYSIS

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Transcript of FABRICATION OF WORKING MODEL OF FRICTION STIR WELDING AND DESIGN OF PROBE AND ANALYSIS