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Friction Stir Welding Tool Design Measurements

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Abstract

We developed a clamping system and an instrumented setup for a vertical milling machine for friction stir welding (FSW) operations and measuring the process forces. Taking into account the gap formation (i.e., lateral movement) and transverse movement of the workpiece, a new type of adjustable fixture was designed to hold the workpiece being welded. For force measurement, a strain gauge based force dynamometer was designed, developed and fabricated. The strain gauges were fitted into the specially designed octagonal members to support the welding plates. When the welding force was applied onto the plates, the load was transferred to the octagonal members and strain was induced in the member. The strains of the strain gauges were measured in terms of voltages using a Wheatstone bridge. To acquire forces in FSW operations, a data acquisition system with the necessary hardware and software was devised and connected to the developed setup. The developed setup was tested in actual welding operations. It is found that the proposed setup can be used in milling machine to perform FSW operations.

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Author information

Affiliations

  1. Department of Mechanical Engineering, IIT, Guwahati, 781039, India

    Biswajit Parida, Shiv Dayal Vishwakarma & Sukhomay Pal

Corresponding author

Correspondence to Sukhomay Pal.

Additional information

Recommended by Associate Editor Sung Lim Ko

B. Parida is a research scholar in the Department of Mechanical Engineering, IIT Guwahati. His research topic is related to the experimental investigation of friction stir welding process.

S. D. Vishwakarma is currently working as a manager in Tata Motors Ltd, Pune. His current research interests include manufacturing and design.

Sukhomay Pal is an assistant professor in the Department of Mechanical Engineering, IIT Guwahati. His research interests include welding process monitoring and control, modeling and optimization of manufacturing processes using soft-computing techniques.

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Parida, B., Vishwakarma, S.D. & Pal, S. Design and development of fixture and force measuring system for friction stir welding process using strain gauges. J Mech Sci Technol 29, 739–749 (2015). https://doi.org/10.1007/s12206-015-0134-x

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  • DOI : https://doi.org/10.1007/s12206-015-0134-x

Keywords

  • Friction stir welding
  • Fixture
  • Strain gauge
  • Force measuring system
  • Elastic member
  • Plunging force
  • Amplification

Friction Stir Welding Tool Design Measurements

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