An experimental and simulation validation of residual stress measurement for manufacturing of friction stir processing tool

826-836Residual stresses have been considered to be an important parameter when friction stir processing (FSP) tool is to be manufactured. FSP has often been used for surface modification and fabrication of surface composites. Involuntary residual stress in a designed tool may cause it to fail before due time. Because of this, the knowledge about the stresses on the tool probe after its machining has been considered to be desirable. The present research has focused on the analysis of the residual stresses on the tip and periphery of the FSP tool probe which has been manufactured using H13 tool steel material during the turning processes on a CNC lathe machine. The experiments have been performed on two different types of tool probes, namely circular, tapered circular probes. ABAQUS/CAE simulation has been performed for circular and tapered circular probe, as the provision of a sustainable, simple and reasonable model to analyze the machining processes (using ABAQUS/CAE software) has been the primary objective of this research. The results have been found to be within a close range of the experimental observations. The same model can thus be applied to other geometries

An experimental and simulation validation of residual stress measurement for manufacturing of friction stir processing tool

Residual stresses have been considered to be an important parameter when friction stir processing (FSP) tool is to be manufactured. FSP has often been used for surface modification and fabrication of surface composites. Involuntary residual stress in a designed tool may cause it to fail before due time. Because of this, the knowledge about the stresses on the tool probe after its machining has been considered to be desirable. The present research has focused on the analysis of the residual stresses on the tip and periphery of the FSP tool probe which has been manufactured using H13 tool steel material during the turning processes on a CNC lathe machine. The experiments have been performed on two different types of tool probes, namely circular, tapered circular probes. ABAQUS/CAE simulation has been performed for circular and tapered circular probe, as the provision of a sustainable, simple and reasonable model to analyze the machining processes (using ABAQUS/CAE software) has been the primary objective of this research. The results have been found to be within a close range of the experimental observations. The same model can thus be applied to other geometries

Mechanical and tribological properties of AA7075-T6 metal matrix composite reinforced with ceramic particles and aloevera ash via Friction stir processing

Mechanical and wear properties of AA7075-T6 reinforced with SiC and Aloevera ash, fabricated using Friction stir processing (FSP) are investigated in this study. Due to less density, easy availability, and cost-effectiveness, aloevera ash is considered as one of the reinforcements. FSP is done using a square tool pin profile, at different tool rotational speeds. To study wear behaviour, pin on disc test is carried out on High Temperature Rotary Tribometer at 20N, 30N and 40N applied load. Wear increases on increasing the applied load and at 20N load Al+SiC/Aloevera ash composite, processed at 600 tool rpm gave the best results due to the formation of oxide tribolayer. At 30N and 40N applied load Al+SiC composite, processed at 900 tool rpm showed the least wear because of proper scattering of ceramic particles due to high tool rotational speed. Coefficient of friction increases on increasing the applied load and all fabricated composite samples showed a lesser coefficient of friction than the base metal. Microhardness, ductility and Ultimate tensile strength increases on the addition of reinforcement and had a direct relation with tool rpm. Wear morphology was analysed using Scanning Electron Microscope (SEM). Energy Dispersive Spectroscopy (EDS) analysis after wear shows the presence of C, Fe, O, Mg, Zn, Si, Al elements and confirms the formation of an oxide layer which is responsible for decreasing wear loss

Mechanical and wear performance of Al/SiC surface composite prepared through friction stir processing

In the present research work, AA7075 composite reinforced with silicon carbide particles has been fabricated using Friction stir processing (FSP). The silicon carbide particles having a size of 40 μ m were placed in grooves of length 160 mm, width 2 mm, depth 3.5 mm, that were generated on the AA7075 plate. The square pin tool is utilized for fabricating the composite at two different rotational speed i.e. 700 and 1000 rpm. Effect of processing, particle addition and tool rotational speed is analyzed on mechanical and wear properties of the material. On friction stir processing the microhardness value and elongation of the material increased. Reinforcement addition contributed to decrease in ductility and tensile strength while on the contrary microhardness and wear resistance of the material improved. Tool rotational speed showed a direct relation with the tested mechanical and wear properties. Adhesive wear was the prominent wear mechanism and Fe layer formation was observed on the worn surface, contributing to increased wear resistance. These fabricated composites can find vast application in industries like automotive, defence and aerospace