Today, tailored welded blank sheets have found various applications in automotive, aeronautic and many other industrial fields. One of the most efficient methods for production of tailored welded blank sheets is application of the friction stir welding process. In the present article, the effect of friction stir welding parameters on the microstructure and mechanical properties of heterogeneous tailored welded blank sheets made from aluminium alloys of types 5083-H12 and 6061-T6 with the similar thickness of 1.5 mm is studied. The considered parameters are rotational speed of the tool, linear speed of the tool, pin diameter and shoulder diameter. In order to come by a tailored welded blank sheet with optimal mechanical properties, response surface methodology, which is considered as a strong tool in design of experiments, has been employed to design the experiment matrix, and the corresponding experiments have been conducted under laboratory conditions. Tensile strength of tailored welded blank sheets are determined as the relation in the mathematical model. The optimal condition and objective effects of parameters are determined via this relation. Data variance analysis showed that rotational speed and diameter tool have the most and the least effect on tensile strength, respectively. Rotational and linear speed are more effective than pin and shoulder diameter in input heat, which is produced by friction.
Flow forming is an effective process for the manufacturing of thin-walled seamless tubes. It has been found that a number of parameters affect the quality and dimensional precision of flow-formed tubes. In this study, the required flow forming tools are manufactured. The outof-roundness of an annealed and flow-formed AISI 321 steel tubular pre-form is investigated for various levels of effective process parameters experimentally. Taguchi's method is employed to design of experiments (DOE). The parameters considered are the feed rate, the depth of cut and the roller attack angle. The effects and contributions weight and interaction effects of these parameters on the out of roundness as response function are analysed. It is found that the depth of cut is the most important process parameter affecting out of roundness. The out-of-roundness decreases with increase in the depth of cut and it increases with increase in the feed rate and roller attack angle.
Flow forming as a precise locally plastic deformation is applied to fabricate thin-walled seamless tubes. Diametral growth as a dimensional defect that occurrs in a flow-formed tube is studied numerically and experimentally in this article. Flow forming of an AISI 321 steel tube is investigated using a finite element method with a dynamic explicit approach. The efficient parameters on the diametral growth are determined using experimental outcomes. The parameters considered are the thickness reduction (%), the feed rate of the roller (mm/min) and the roller nose radius (mm). Response surface methodology is employed to draw out a mathematical model of the diametral growth with regard to the significant parameters. The gained equation reveals that the thickness reduction is the most significant parameter and feed rate has the slightest effect on the diametral growth. The diametral growth increases with the rise in the thickness reduction and the roller nose radius and it leads to a decrease with a high value of feed rate. The innovation point of view is related to the fact that the high level of roller nose radius covers the efficiency of feed rate.
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