Parametric Optimization of Friction Stir Welding

Project Title

Parametric Optimization of Friction Stir Welding

Project Area of Specialization Mechanical EngineeringProject Summary

Friction stir welding is a newly developed solid state welding technique developed by "The Welding Institute". In our project we will study the parameters affecting friction stir welding process. Then we will perform friction stir welding (butt joint) process on aluminum alloy that is not generally welded by traditional welding technique with the help of our own fabricated friction stir welding tool on three axis cnc milling maching. We will also develop setup to calculate axial force exerted by the friction stir welding tool on the work piece. After the process we will extract standerized sample to perform tensile test and impact test to calculate strength of the welded joint. we will apply taguchi optimization technique to calculate desired optimum parameters. The paraeters under study will be tool rotational speed, tool feed rate and axial force exerted by tool on the welding plates. 

Project Objectives

1- learing about advaned manufacturing technique.

2. practically performing friction stir welding process

3. desing and development of setup to calculate real time axial force.

4. we will learn about advaned manufacturing optimization technique likes taguchi and anova.

Project Implementation Method

after research gap analysis we will select aluminum alloy on which friciton stir welding is to be performed. we will select tool material. all material needed for the completion of project will be purchased. cnc milling maching is present in the department. we will utilize that maching to perform friction stir welding process. setup comprises of strain guages will be installed below the welding plate to calculate axial force. specimens will be extracted out with the help of cnc milling machine according to ASTM standards for tensile and impact test. standard optimization technique will be implemented to obtain optimized parameter. Then process will be performed again utilizing the obtained optimized parameter to ensure optimum result validation.

Benefits of the Project

friction stir welding process is videly used in many industrial processes, like automation and aviation. The optimization performed during the project will help to perform better friction stir welding process in the industry.

Technical Details of Final Deliverable

after the performance of friction stir welding, based on experimentation and testing optimized paramerter that include tool rotation speed, tool feed rate and tool axial force will be calculated for most widely used friction stir welding tool pin profile. 

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Education , Transportation Core Technology Clean TechOther TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	80000
Aluminum alloy plates	Equipment	3	20000	60000
Tool Steel H-13 for tool	Equipment	1	5000	5000
Strain gauge setup	Equipment	1	5000	5000
Testing	Miscellaneous	1	10000	10000