Indian Journal of Science and Technology

Abstract

Friction stir welding is solid state joining process where the energy efficiency is dependant on the selection of tool geometry. The objective of this work is to reduce time consumption in calculating tool geometric parameters using C program. As the tool being of different geometry in concern with different complex operation, the energy generated and the temperature distribution which influenced by efficient energy is to be calculated. The calculation is performed based on the machining different work pieces by adjusting tool parameters of aluminium alloys such as Al6061-T6, Al22024-T6, Al7075-T6. Six different cases had been generated in our work for each Aluminium alloy where different RPM (Rotation Per Minute) such as 200, 400, 600, 800, 1000, 1200 was maintained and compared to translational speed and applied normal force. The Energy and Maximum Temperature obtained using Taper Model and the Cylindrical model is compared based on the data processed during the machining. The proposed energy model equation is helpful in computing these data. Manual calculation in these equation may lead to large consumption. Thus the different tool parametric value can be easily generated by coding these equation in C program and feeding necessary input parameters from users. Thereby it generates the different values at faster rate. From this experiment, it is found that abrupt changes in the process may lead influence the efficiency of welding the material and may affect it. Larger data regarding the tool parameter can be processed easily at less time using C. Different tools have different parametric changes and thereby having knowledge over its parameters may not affect the work pieces. C program help to generate these data. Further improvement can be made by doing same study over different other tools and by coding these different values calculated maybe helpful in tool selection. The study can also be made over similar other welding processes too and also help in prevention of damage of different work pieces. 
Keywords: C-Programming, Energy Model, Friction Stir Welding, Taper Tool, Temperature Model