A novel approach to measure three-dimensional surface topography for stationary shoulder friction stir processing

Surface topography is an important characteristic of the surface integrity, and influences the performance and mechanical properties of the workpiece to a great extent in micro milling SiCp/Al composites. It is evaluated by three-dimensional surface roughness ( Sq) and fractal dimension ( Ds) in this paper. Based on the single factor experiment and the orthogonal experiment, the influence of process parameters (feed per tooth, spindle speed, milling depth, and milling width) on surface topography is studied. The results show that Sq is mainly affected by milling width and milling depth and optimal results for minimum Sq are: ae = 1.5 mm, ap = 0.08 mm, n = 12000 r/min, and fz=1 μm/z. While Ds is mainly affected by milling width and optimal parameters for maximum Ds are: ae=1 mm, n = 14000 r/min, fz = 1.5 μm/z and ap = 0.12 mm. There is a weak negative correlation between Sq and Ds. In addition, Ds is more sensitive to the main defects and in general a large Ds corresponds to a good surface.

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A novel approach for producing in situ Al-Al2Cu composite via friction stir processing

Materials Research Express ◽

10.1088/2053-1591/aaf7b9 ◽

2018 ◽

Vol 6 (3) ◽

pp. 036528 ◽

Cited By ~ 1

Author(s):

M Azizieh ◽

M A G Dezfuli ◽

Z Balak ◽

H S Kim

Keyword(s):

Friction Stir Processing ◽

Friction Stir ◽

Novel Approach

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Validity of two dimensional modeling for scattering of elastic waves by three dimensional surface topography of arbitrary shape

International Journal of Rock Mechanics and Mining Sciences & Geomechanics Abstracts ◽

10.1016/0148-9062(91)90626-w ◽

1991 ◽

Vol 28 (4) ◽

pp. A202

Keyword(s):

Surface Topography ◽

Elastic Waves ◽

Arbitrary Shape ◽

Three Dimensional ◽

Two Dimensional ◽

Dimensional Modeling ◽

Scattering Of Elastic Waves ◽

Dimensional Surface

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Calibration of translational tables for use in three-dimensional surface topography measurement systems

International Journal of Machine Tools and Manufacture ◽

10.1016/0890-6955(94)90102-3 ◽

1994 ◽

Vol 34 (2) ◽

pp. 211-224 ◽

Cited By ~ 5

Author(s):

E. Mainsah ◽

P.J. Sullivan ◽

K.J. Stout

Keyword(s):

Surface Topography ◽

Three Dimensional ◽

Measurement Systems ◽

Dimensional Surface

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Simulation of Friction Stir Processing with Internally Cooled Tool

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.560 ◽

2012 ◽

Vol 445 ◽

pp. 560-565

Author(s):

A.N. Albakri ◽

B. Mansoor ◽

H. Nassar ◽

M.K. Khraisheh

Keyword(s):

Grain Refinement ◽

Friction Stir Processing ◽

Three Dimensional ◽

Excessive Heat ◽

Friction Stir ◽

Processed Material ◽

Internally Cooled ◽

Division Process ◽

Tool Cooling ◽

Temperature Levels

Friction stir processing (FSP) is considered to be a promising sustainable technique for grain refinement of metallic alloys. The heat generated during FSP promotes dynamic recrystallization in processed material which is essential for grain sub-division process. However, excessive heat generation can lead to high temperatures of >300°C that may cause abnormal grain growth in the processed material. On the other hand, repetitive high temperature heating cycles can reduce the lifetime of the FSP tool. Therefore, it is essential to manage the process heat not only to achieve homogeneity and finer grain sizes in the processed material but also to reduce tool wear. In this work, friction stir processing of AZ31B Mg with an internally cooled FSP tool is simulated by a three-dimensional CFD model. We have studied the effect of rapid tool cooling on temperature and flow stress distribution in processed material. Additionally, the grain size and hardness of the processed material is estimated by using Zener-Holloman and Hall-Petch based relationships. It was found that FSP with internally cooled tool is a promising approach that effectively controls temperature levels during processing. Therefore it enables the achievement of better mechanical properties by effective grain refinement and has a positive effect on tool life.

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