A multi-objective optimization of the friction stir welding process using RSM-based-desirability function approach for joining aluminum alloy 6063-T6 pipes

Senthil, S. M.; Parameshwaran, R.; Nathan, S. Ragu; Kumar, M. Bhuvanesh; Deepandurai, K.

doi:10.1007/s00158-020-02542-2

“…Based on the desirability function techniques was used to predict the best results of both responses. It detects a point that improves the desirability function [23]. For validating the developed models, some solutions were selected randomly.…”

Section: Wwr =mentioning

confidence: 99%

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Boopathi¹,

Myilsamy²

2021

SV-JME

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In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

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“…Based on the desirability function, techniques were used to predict the best results of both responses. This process detects a point that improves the desirability function [23]. For validating the developed models, some solutions were selected randomly.…”

Section: Multi-objective Optimization a Nd Validation Of Predictionmentioning

confidence: 99%

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Sampath¹,

Myilsamy²

2021

SV-JME

2

0

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In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

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“…It has been successfully applied into joining of many materials in particular light metals whose melting points are relatively low including 2XXX and 7XXX aluminum alloys that are not fusion weldable [62,63]. For example, Senthil et al optimized process parameters to successfully weld AA6063-T6 pipes [64]; Mehri et al [65] successfully welded 7075-T6 aluminum alloy (AA) thin sheet; Robe et al [66] applied the rigid-ALE finite element approach that is capable of including a complex tool geometry to quickly obtain the quasi-periodic thermal state for dissimilar joining of 2XXX/7XXX aluminum alloys. As examples for dissimilar joining among light metals, Zhang et al [67] joined AZ31/AM60 dissimilar Mg alloys using higher and lower rotation speeds (together with associated sets of parameters) to understand the effect of microstructure and texture distribution on mechanical properties and deformation behaviors; Abolusoro et al [68] used FSW to join 6101-T6 and 7075-T651.…”

Section: Friction Stirmentioning

confidence: 99%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

¹

,

Yang

²

,

Wei

³

et al. 2020

Journal of Manufacturing Science and Engineering

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Welding is a major manufacturing process that joins two or more pieces of materials together through heating/mixing them followed by cooling/solidification. The goal of welding manufacturing is to join materials together to meet service requirements at lowest costs. Advanced welding manufacturing is to use scientific methods to realize this goal. This paper views advanced welding manufacturing as a three step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the welding parameters by adjusting the welding parameters based on such real-time sensing and feedback control. The paper analyzes how these three steps depend on process properties/capabilities, process innovations, predictive models, numerical models for fluid dynamics, numerical models for structures, real-time sensing, and dynamic control. The paper also identifies the challenges in obtaining ideal solutions and reviews/analyzes the existing efforts toward better solutions. Special attention and analysis have been given to (1) gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) as benchmark processes for penetration and materials filling; (2) keyhole plasma arc welding (PAW), keyhole-tungsten inert gas (K-TIG), and keyhole laser welding as improved/capable penetrative processes; (3) friction stir welding (FSW) ......

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A multi-objective optimization of the friction stir welding process using RSM-based-desirability function approach for joining aluminum alloy 6063-T6 pipes

Cited by 80 publications

References 28 publications

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

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