Numerical analysis of friction stir welding process

Friction stir welding (FSW), which has several advantages over the conventional welding processes, is a solid-state welding process where no gross melting of the material being welded takes place. Despite significant advances over the last decade, the fundamental knowledge of thermomechanical processes during FSW is still not completely understood. To gain physical insight into the FSW process and the evaluation of the critical parameters, the development of models and simulation techniques is a necessity. In this article, the available literature on modeling of FSW has been reviewed followed by details of an attempt to understand the interaction between process parameters from a simulation study, performed using commercially available nonlinear finite element (FE) code DEFORM. The distributions of temperature, residual stress, strain, and strain rates were analyzed across various regions of the weld apart from material flow as a means of evaluating process efficiency and the quality of the weld. The distribution of process parameters is of importance in the prediction of the occurrence of welding defects, and to locate areas of concern for the metallurgist. The suitability of this modeling tool to simulate the FSW process has been discussed. The lack of the detailed material constitutive information and other thermal and physical properties at conditions such as very high strain rates and elevated temperatures seems to be the limiting factor while modeling the FSW process

An optimization-based algorithm for shunt active filter under distorted supply voltages

When the supply voltages are balanced and sinusoidal, load compensation can give both unity power factor (UPF) and perfect harmonic cancellation (PHC) source currents. But under distorted supply voltages, achieving both UPF and PHC currents are not possible and contradictory to each other. Hence there should be an optimal performance between these two important compensation goals. This paper presents an optimal control algorithm for load compensation under unbalanced and distorted supply voltages. In this algorithm source currents are compensated for reactive, imbalance components and harmonic distortions set by the limits. By satisfying the harmonic distortion limits and power balance, this algorithm gives the source currents which will provide the maximum achievable power factor. The detailed simulation results using MATLAB are presented to support the performance of the proposed optimal control algorithm

Tribological behavior of Al−Si/SiCpAl-Si/SiC_p composites/automobile brake pad system under dry sliding conditions

Tribological behavior of stir-cast $Al-Si/SiC_p$ composites against automobile brake pad material was studied using Pin-on-Disc tribo-tester. The Al-metal matrix composite (Al-MMC) material was used as disc, whereas the brake pad material forms the pin. It has been found that both wear rate and friction coefficient vary with both applied normal load and sliding speed. With increase in the applied normal load, the wear rate was observed to increase whereas the friction coefficient decreases. However, both the wear rate and friction coefficients were observed to vary proportionally with the sliding speed. During the wear tests, formation of a tribo-layer was observed, presence of which can affect the wear behavior, apart from acting as a source of wear debris. Tribo-layer formed over the worn disc surfaces was found to be heterogeneous in nature. Morphology and topography of worn surfaces and debris were studied using scanning electron microscope (SEM). Chemical composition of different wear products was obtained using electron probe micro analyzer (EPMA) and X-ray diffraction (XRD) techniques. Possible wear mechanisms operative in Al-MMC-brake pad tribo-couple have been discussed

Tribological behavior of Al−Si/SiCpAl-Si/SiC_p composites/automobile brake pad system under dry sliding conditions

Tribological behavior of stir-cast $Al-Si/SiC_p$ composites against automobile brake pad material was studied using Pin-on-Disc tribo-tester. The Al-metal matrix composite (Al-MMC) material was used as disc, whereas the brake pad material forms the pin. It has been found that both wear rate and friction coefficient vary with both applied normal load and sliding speed. With increase in the applied normal load, the wear rate was observed to increase whereas the friction coefficient decreases. However, both the wear rate and friction coefficients were observed to vary proportionally with the sliding speed. During the wear tests, formation of a tribo-layer was observed, presence of which can affect the wear behavior, apart from acting as a source of wear debris. Tribo-layer formed over the worn disc surfaces was found to be heterogeneous in nature. Morphology and topography of worn surfaces and debris were studied using scanning electron microscope (SEM). Chemical composition of different wear products was obtained using electron probe micro analyzer (EPMA) and X-ray diffraction (XRD) techniques. Possible wear mechanisms operative in Al-MMC-brake pad tribo-couple have been discussed