Applied Mechanics and Materials Vols. 766-767

Abstract: The wear performance of the mild steel under different Abrasive Flow Machining (AFM) conditions was studied. Wear properties of mild steel are considerably affected by the process parameters of AFM.The effect of extrusion pressure, abrasive concentration and abrasive size during AFM on wear performance were investigated using a reciprocating wear testing machine. Experiments were conducted according to 2³ factorial design of experiments for this purpose. The contribution of the process parameters on wear resistance were obtained performing Analysis of Variance (ANOVA). The wear rate, specific wear coefficient (Ks), wear resistance, fatigue strength and surface hardness are also considerably affected by the process parameters abrasive concentration, extrusion pressure and abrasive size.

Abstract: The Electrical Discharge Machine (EDM), parameters are investigated during the machining of Inconel 825 by using different tool geometry of zirconium copper electrode. Demand for better MRR, SR, and lower Tool Wear Rate are increasing recently for all materials, the low rigidity and high material removal rate of Inconel alloy offers a challenging task in obtaining output responses. The analysis of output responses such as Metal Removal Rate (MRR) of Inconel 825 material is carried out an excellent result can be obtained by using Taguchi L16 Orthogonal Array under different conditions of Parameters. The response of MRR is considered for improving machining efficiency. Optimal combination of parameters was obtained Taguchi optimization technique. The confirmation experiments results shows that the significant improvement in output responses was obtained. ANOVA have been used to analyze the contribution of individual parameters on Material Removal Rate. The experimental result demonstrates that the Taguchi method satisfies the practical requirements.

Abstract: Improving the Material Removal Rate (MRR), reduce Tool Wear Rate (TWR), achieve the good Surface Finish (SF) and Over Cut (OC) are very demanding in Electrical Discharging Machining (EDM). This paper focused on performance of Silicon powder mixed with kerosene servotherm dielectric medium in EDM of Monel 400. The optimum range of Silicon powder, Graphite powder 6g mixes with the dielectric medium of kerosene servotherm (75:25) were developed experimentally. It was reported slightly more MRR, very low TWR, better OC and good surface finish (SF) in Monel 400.

Abstract: Titanium alloys are attractive materials used in different engineering applications, due to its excellent combination of properties such as high strength to weight ratio, good corrosion resistance and high temperature applicability. They are also being used increasingly in chemical process, automotive, biomedical and nuclear plant. When machining of Titanium alloys with traditional tools the tool wear rate high. Because of high chemical reactivity and low modulus of elasticity resulting high cutting temperature and strong adhesion between the tool and work piece materials. The poly crystalline diamond (PCD) cutting tool is used for the turning experiment. The turning parameters for the experimental work are cutting speed, feed, nose radius, and depth of cut. From the results, analysis of the influences of the individual parameters on the surface roughness have been carried out. Fuzzy modeling technique is effectively used to predict the surface roughness in the machining of titanium alloy.

Abstract: The life of the components used under slurry abrasion conditions is governed by the process variables, properties of the abrasive materials in the slurry and the material properties. Slurry wear, abrasion occurs in Extruders, pumps and pipe transport slurry of minerals and ores in mineral processing industries. In the present research, the effect of operating variables such as abrasive particle size and shape, slurry concentration and normal load on the abrasive slurry wear behavior of the weld deposit martensitic steel surface produced by the Manual Metal Arc Welding Hard facing process was conceded out. The testing was conceded out using the slurry abrasion test rig. The silica sand particles were used as the abrasive medium. The qualitative nature of wear pattern and morphology of the worn out surface was examined under scanning electron microscope (SEM). These features were correlated with operating parameters.

Abstract: The main objective of this work is to compare the friction stir welding with plasma arc welding processes using dissimilar materials. The materials used AA 8011 and AA 6061.The factors compared in this process are the weld quality, different welding feed and rotation speed. The effects of welding processes on the impact test and micro hardness behaviour were studied. Morphological analysis was carried out using SEM analysis. Taguchi’s, DOE method and ANOVA is done to find the parameters that have highest influence on weld strength. The results show that the FSW joints exhibit superior tensile and fatigue, impact test, and micro hardness properties compared to plasma arc welding. This is mainly due to the presence of mechanical properties are superior to plasma arc welding. Keywords: Friction stir welding, SEM, AA 8011, AA 6061, plasma arc welding, ANOVA, and DOE

Abstract: Aluminum alloys exhibit poor weldability by conventional fusion welding process. The heat treatable aluminum alloy AA2014 is extensively used in the aircraft industry because it has good ductility and high strength to weight ratio. In this paper the effects of welding parameters and tool profile on the mechanical properties of friction stir welded butt joints of dissimilar aluminum alloy sheets AA6082 and AA2014. The process parameters such as rotational speed, transverse speed and axial forces were considered. The effect of parameters on weld quality was analyzed. Hardness and tensile tests are carried out at room temperature to examine the mechanical properties of the welded joints. The joints produced with straight square tool pin profile have higher ultimate tensile strength, whereas the straight cylindrical tool pin profile results in lower tensile strength.

Abstract: Friction stir welding is a solid state welding process that uses a rotating tool to amalgamate two metals by the frictional heat generated. Recent developments in FSW of aluminium have been exploited in aerospace, marine and transport industries. The friction stir welding on aluminium metal generates heat which has detrimental effects on the system in the long run. The heat generated, due to the friction developed, has to be reduced to provide a constant thermal environment for the tool and the workpiece. This work focuses on the conception to develop a water cooled tool holder to reduce the excess temperature thereby protecting the spindle bearing. The current paper elucidates on the design and parameters of water cooled tool holder and spring loaded seal, its implementation and the results obtained by friction stir welding of aluminum.

Abstract: Aluminium alloys are widely used in automotive, aerospace and ship industries as high strength-to-weight ratio materials. With the increasing demand for lightweight components, their application is becoming more extensive. To study the effect of Tool geometries on Metallurgical & mechanical properties of Aluminum alloy 5052 H32 using friction stir welding process. To briefly discuss about the conditions & conclude the suitable condition for Aluminium alloy 5052 H32. To plot and conclude the hardness values for various conditions. The tool material Mild Steel IS 2062 FE410 cone type and thread type has been selected for this research for various speeds to find suitable condition. The micro structure and macro structure have checking the structural formation of welded area in details to know it the strength of the joining. The present friction stir welding research is implementing the new tools for the current issues; here we try to implement new material for already available tools.

Abstract: In the present method the effect of welding speed, axial force, tool rotational speed and shoulder penetration on the mechanical properties of Aluminium alloy 6061 butt joint produced by Friction Stir Welding (FSW) is analyzed. The mechanical behavior properties like Yield Strength, Tensile Strength and % of Elongation has been tested using 5 mm thick plate. The tool used for conducting the experiment was High Speed Steel (HSS). Tensile Strength, Yield Strength and Percentage of Elongation of FSW Al alloy 6061 has been evaluated under different processing condition using Taguchi’s design. The optimum results had been obtained using main effects plot using S/N ratio values. Tool rotation speed has been found dominant factor for Tensile Strength followed by feed and shoulder penetration. Shoulder diameter shows the minimal effect on Tensile Strength compared to other parameters.