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Investigation of Mechanical Properties of MS Rod Joined by Friction Welding Using Various End Preparations

1Jagroop Singh, 2Rakesh Kumar1,2Dept. of ME, North West Institute of Engg. and Tech., Dhudike, Moga, Punjab, India

AbstractFriction welding is one of the most important types of solid state welding process and it involves moving one component relative to the other component to generate required amount of heat and then applying lateral force (called upsetting force) to plastically displace fuse materials. Now a days Friction welding is most commonly used in industry that is aeronautical engineering, automobile engineering, submarine industry and heavy industry.

In the present study, an experimental setup was designed in order to achieve friction welding of MS rods. The diameter of MS rod 20mm and length 150mm+150mm. A step was performed on the specimen who had diameter 10mm and length (recess dimension) 5,10,15,20 and 25mm respectively. The fixed parameters were friction time, forge time, rotational speed and variable parameters were recess dimensions of the specimens and friction pressure applying manually.

In this study, the investigation of mechanical properties of MS rod joined by friction welding using various end preparations and afterwards the mechanical properties such as tensile test, hardness test, torsion test and ultrasonic test were experimentally determined. On the basis of results obtained from the experimentation, the graphs were plotted.

KeywordsFriction Welding; Lathe Machine; MS Rod; Braking System; Tensile Test; Hardness Test; Torque Testing; Ultrasonic Testing

l. IntroductionWelding is the process of joining two similar or dissimilar metals with or without the application of pressure wherein coalescence is produced by the heat generated through arc.

Friction Welding (FW) is defined by the different authors by adopting various definitions of friction welding. The friction welding is a solid state welding process wherein stationary work piece held in contact with a rotating work piece results in generation of heat at the interface of the work pieces which in turn is responsible for the joint formation. Prominent parameters used in friction welding are forging (upset) time, forging (upset) pressure, friction time, friction pressure, temperature, burn off length and rotation speed.

In this present work, Different end preparations will be prepared and welded joint will be investigated for its mechanical behaviour. The main fixed parameters in friction welding are the rotational speed, friction time, forging time and the variable parameters are recess dimensions of the specimens and friction pressure applying manually. The design and dimensions of the specimens are shown in fig. 1.

Fig. 1: The Design and Dimensions of Specimens

ll. PrincipleSTEP 1:- The two components to be friction welded are held in axial alignment.STEP 2:- One component that is held in chucking spindle of the machine is rotated and accelerated to the desired speed.STEP 3:- The other component that is held in the movable clamp is moved forward to come into pressure contact with the rotating component.STEP 4:- Pressure and rotation are maintained until the resulting high temp makes the component’s metal plastic for welding with sufficient metal behind the interface becoming softened to permit the components to be forged together. During this period metal is slowly extruded from the weld region to form an upset.

Fig. 2: Basic Steps of Principle of Friction Welding

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III. Material SelectionTwo mild steel rods of diameter 20mm have been taken initially.

Dimensions: Mild Steel rod Big diameter:-20mm Small diameter:-10mm Length:-150mm+150mm Recess Dimension:-5mm, 10mm, 15mm, 20mm, 25mm respectively.

lV. Experimental WorkThe experimental setup has been fabricated for the production of friction welded joints. For this, the conventional heavy duty direct drive lathe machine has been modified to suit the requirements of friction welding machine. The existing lathe machine model “HMT Vikram”, maximum speed 250-2200 rpm was used for this experimentation work. The modification was done by the fitting one more three jaw chuck on tail stock on the lathe machine. fig. 3 shows the fabricated friction welding setup. The bars were cleaned mechanically and chemically in order to make them free from oil, dirt, grease etc. Samples of 20mm in diameter and 150mm+150mm in length were used, they were cut from the power hacksaw and the facing, turning, drilling and boring operation were done on the lathe machine for the production of friction welds. These specimens were then fitted on the friction welding setup.

Fig. 3: Friction Welding Machine Setup

Fig. 4: The Turning Specimens (Male)

Fig. 5: The Boring Specimens (Female)

Fig. 6: The Alignment Phase of the Friction Welding Process

Fig. 7: The Constant Phase of the Friction Welding Process

Fig. 8: The Heating Phase of the Friction Welding Process

Fig. 9: The Forge Phase of the Friction Welding Process

Fig. 10: The Complete Process of the Friction Welding

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Fig. 11: The Complete All Sizes of Friction Welding Specimens

V. Result & DiscussionThis section describes the results obtained after the experimental work of friction welding on lathe machine for mild steel rods. Table 1 below shows the result of experimental work. The two parts of mild steel rods are properly welded during the experiment. The welding process performed by fixed parameters such as friction time, forge time, speed and variable parameters of recess dimensions of specimens and by applying sufficient pressure to the tailstock end manually Friction welded parts were subjected to variety of mechanical tests to determine their suitability for the anticipated service applications. They were necessary to carry out so as to ensure the quality, reliability and strength of the welded joints. In our investigation, mechanical properties like tensile test, Rockwell hardness test, torsion test and ultrasonic test were evaluated.

Table 1: Shows the Results of Friction Welded Specimen

A. Tensile TestTensile test was performed on the Universal Testing Machine of the make FIE, model UTE-400, which had a capacity of 400KN. The machine used for tensile testing had a computer interface and data was generated on the computer and on the basis of this data the graphs were plotter. The gauge length of the specimens was maintained according to the weld interface at the centre of the gauge length. The sample was then fitted firmly between the jaws of the machine and load was applied.

Fig. 12: Universal Testing Machine Setup

Table 2: Shows the Results of Tensile Tests

Fig. 13: The Fracture Specimens of Tensile Test

B. Hardness TestFor hardness testing, Digital Rockwell hardness testing machine was used, FIE make, model RASN-EB1, which had a capacity of 60-250 kgf. In this test, a diamond indenter was used and the hardness variation on the weld interface of the specimens obtained by applying a constant load of 100kgf. The indentations were made at the weld interface at fixed intervals, so as to find out the hardness values. The results obtained are reported in Table 3 and the basis of the obtained values of hardness, the graph was plotted.

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Fig. 14: Digital Rockwell Hardness Tester

Table 3: Shows the Results of Rockwell Hardness Value

C. Ultrasonic TestUltrasonic testing was performed on the Ultrasonic Flaw Detector EPOCH-1000i, Sr. NO:-090048910, of the make Olympus, test method ASME Sec-V, Article-IV. It was performed Institute for Auto Parts and Hand Tools Technology, Ludhiana. The EPOCH- 1000 Series front panel shown in fig. 15 on features a combination of direct access keys, navigation arrows and dynamic function and parameter access keys to optimize the usability of the instrument in any mode. The layout of the front panel provide direct access to common inspection parameters and easy to adjustment of values from either side of the instrument without obstructing the view of display.

Fig. 15: The EPOCH 1000i Hardware User Interface Elements

Fig. 16: The Specimens of Ultrasonic Tests

Table 4: Shows the Results of Ultrasonic Tests

D. Torsion TestTorsion testing was performed on the Computerized Torque Testing Machine, Sr. NO:-29/2011-12, Model No:-OTT-211, of the make Real Scientific Corporation, which had a capacity of 5000N. It was performed Central Institute of Hand Tools Technology, Jalandhar.

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Fig. 17: Computerized Torsion Testing Machine

Table 5: Shows the Results of Torsion Testing

VI. ConclusionThis section describes the conclusion obtained the experimental work of friction welding on lathe machine for mild steel rods. The present investigations carried to achieve the objectives of the study have lead to the following conclusions:

It is safe on lathe machine to perform the friction welding up 1. to rod diameter 20mm with good mechanical properties.The mechanical properties of the friction welds were found 2. to vary with the recess dimensions, which indicates that the recess dimension of specimens are an important welding parameter.The maximum tensile strength for welded rods was achieved 3. at the recess dimension of 25mm.It has also been observed that the maximum torque for 4. weldments was also acceptable at the recess dimension of 25mm.The value of hardness also maximum at the recess dimension 5. of 25mm.

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Er. Jagroop Singh received his diploma in mechanical Mechanical engineering from IASE Deemed University Sardarshar, Rajasthan in 2007, engineering from SBS Polytechnic college Patti (PSBTE Chandigarh) in 2004. B.Tech degree in the M.Tech degree in mechanical engineering from North West Institute of Engineering and Technology, Moga.

(PTU Jalandhar). He is Assistatant Professor, with Department of Mechanical Engg. Anand college of Engineering and Management Kapurthala, Punjab. He has more than 3 years teaching experience in mechanical engineering and 6 years in industry.