scholarly journals A Systematic Study on the Effects of Process Parameters on Spinning of Thin-Walled Curved Surface Parts With 2195 Al-Li Alloy Tailor Welded Blanks Produced by FSW

2021 ◽  
Vol 8 ◽  
Author(s):  
Hongrui Zhang ◽  
Mei Zhan ◽  
Zebang Zheng ◽  
Rui Li ◽  
Wei Lyu ◽  
...  
Keyword(s):  
Process Parameters ◽  
Green Manufacturing ◽  
Lower Surface ◽  
Attack Angle ◽  
Curved Surface ◽  
Nose Radius ◽  
Friction Stir ◽  
Tailor Welded Blanks ◽  
Thin Walled ◽  
Curved Surface Parts

The manufacturing process is inevitably accompanied with the production of scraps, which leads to resource waste and environmental pollution. Recycling and remanufacturing are the most commonly used approaches for metal scraps due to their well-established advantages from economic and environmental perspectives. In this study, spinning experiments with 2195 Al-Li alloy tailor welded blanks produced by friction stir welding from metal scraps were conducted under different process parameter designs. And then the effects of various process parameters on spinning of thin-walled curved surface parts were systematically studied. The results of the corresponding experimental groups show that the roller attack angle, the spinning clearance, and the installation method of tailor welded blanks have the most significant effect on the weld torsion angle. In addition, it was found that along the longitude direction of spun parts, the surface roughnesses of the weld of spun parts were greatly improved under the roller nose radius of 10 mm, the spinning clearance of 1.0 mm, the constant linear velocity, and the installation method of tailor welded blanks (the lower surface of tailor welded blanks is spun by rollers), while the process parameters have little significant effect on the surface roughness along the latitude direction of spun parts. Furthermore, it can be concluded that the forming profiles of spun parts fitted the mandrel well under the roller nose radius of 6 mm, double rollers, the roller attack angle of 30° and 45°, spinning clearance of 1.5 mm, and the installation method of tailor welded blanks (the upper surface of tailor welded blanks is spun by rollers). The research results will provide guidance for the precise spinning of thin-walled curved surface parts with tailor welded blanks. Thereby, it is also beneficial for green manufacturing involving recycling and remanufacturing of metal scraps.

Clamping Deformation Analysis Research Based on a Flexible Clamping Fixture of Thin-Walled Curved Surface Parts

2012 ◽  
Vol 476-478 ◽  
pp. 2028-2031 ◽  
Author(s):  
Li Gang Qu ◽  
Hai Bin Liu
Keyword(s):  
Curved Surface ◽  
Deformation Analysis ◽  
Deformation Index ◽  
General Flow ◽  
Thin Walled ◽  
Curved Surface Parts

According to the space surface positioning principle, in this paper, to the practical need for clamping of the thin-walled curved surface parts as the background, the principles and methods of the production of flexible positioning surface are studied and a flexible clamping fixture is designed. It also elaborated the general flow of deformation analysis to the gripping parts with ANSYS. In addition, it analyzed the gripping deformation of the known surface parts, and validated the deformation index of the clamping fixtures.

scholarly journals Effects of Process Parameters on Surface Straightness of Variable-Section Conical Parts during Hot Power Spinning

2021 ◽  
Vol 11 (17) ◽  
pp. 8187
Author(s):  
Yanli Liu ◽  
Xuedao Shu ◽  
Zewei Cen ◽  
Zixuan Li ◽  
Bohai Ye
Keyword(s):  
Process Parameters ◽  
Rotation Rate ◽  
Orthogonal Design ◽  
Feed Ratio ◽  
Key Factors ◽  
Nose Radius ◽  
Power Spinning ◽  
Deformation Law ◽  
Variable Section ◽  
Thin Walled

How to form high-quality variable-section thin-walled conical parts through power spinning is a key issue for superalloy spinning manufacturing. A study into the hot power spinning deformation law of variable-section thin-walled conical parts and the effects of process parameters on surface straightness of forming quality are delineated in this paper. Through the establishment of finite element (FE) models using the single-factor and orthogonal design of experiments, the effects of four key process parameters on the surface straightness have been investigated and the optimal combination of process parameters have been yielded. These key factors include spinning temperature, roller nose radius, mandrel rotation rate and roller feed ratio. The results of FE simulation have been validated through the comparison of the surface straightness of modeled parts with those measured during a spinning experiment. The results reveal that, among the studied process parameters, the spinning temperature has the greatest influence on the surface straightness, followed by the roller nose radius and mandrel rotation rate, and the roller feed ratio has the least influence on the straightness. Larger mandrel rotation rate, smaller feed ratio and suitable spinning temperature can enhance the surface straightness.

scholarly journals Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1157
Author(s):  
Danka Labus Zlatanovic ◽  
Sebastian Balos ◽  
Jean Pierre Bergmann ◽  
Stefan Rasche ◽  
Milan Pecanac ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Spot Welding ◽  
Minimum Energy ◽  
Tool Geometry ◽  
Friction Stir ◽  
Minimum Energy Consumption ◽  
Punch Test ◽  
Wide Range ◽  
Lap Welding

Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

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