Dr. KAUSHAL BHAVSAR | Kadi Sarva Vishva Vidhyalaya (original) (raw)
Papers by Dr. KAUSHAL BHAVSAR
International Journal For Science Technology And Engineering, 2016
Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new join... more Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new joining technique. Especially high strength aluminium alloys can be welded with large advantages as compared to conventional fusion welding processes. Friction stir welding (FSW) of aluminium components using both fixed and variable gap bobbin tools has been demonstrated by several researchers, and reportedly these procedures were relatively easy to develop. Bobbin welds do not have an initial phase where the welding tool probe is plunged axially into the work piece as is done in conventional FSW. Bobbin welds are typically started by driving onto the edge of the plate or from a pre-drilled hole with an initially slow travel speed until plastic deformation starts, followed by acceleration of the travel speed to the final steady state value. The objective of current paper is to examine and summarize information for change in mechanical properties for bobbin tool friction stir welding (FSW) fo...
Materials Today: Proceedings, 2020
International Journal for Research in Applied Science and Engineering Technology, Sep 30, 2017
International Journal of Trend in Scientific Research and Development, 2018
INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY, 2023
Friction stirs processing (FSP) is a method of changing the properties of metal through intense, ... more Friction stirs processing (FSP) is a method of changing the properties of metal through intense, localized deformation. Where Friction Stir Welding (FSW) is Mechanical joining properties are dramatically pushed into deterioration when a tunnel defect is formed. FST is effect found due to regulated heat input and regulated material flow. Sometimes defects in the weld are generated applying certain variations in welding parameters. In this study, the tunnel formation in AA 3102 was experimentally studied by taking various parameter incorporating speed and feed. The effect of tunnel formation was evaluated by Radiography test. Here we are creating the tunnel through the length and which dimension can be control by tool geometry, spindle speed, and feed rate. This experimental investigation covers methodology to enhance the word "defect" to "tunnelling effect" which is created by changing some parameter during processing and welding.
1ME scholar, Mechanical Department, LDRP-ITR, Gandhinagar, India 2Profesor, Mechanical Department... more 1ME scholar, Mechanical Department, LDRP-ITR, Gandhinagar, India 2Profesor, Mechanical Department, LDRP-ITR, Gandhinagar, India ---------------------------------------------------------------------***--------------------------------------------------------------------Abstract Friction stir welding and friction stir spot welding are newly evolved solid state joining processes. These techniques are energy efficient, economical, better than conventional welding processes, and versatile. FSW and FSSW are promising and found to be the very important progression in metal joining area. In this review paper, the basic processes and their various parameters are included for understanding of the FSW and FSSW. While most of the information is related to Aluminium and magnesium alloys, important results are also available for other metal and alloys. At this scenario, technology advancement has growing faster and outpaced the fundamental need to just join the materials and their microstructural ...
International Journal For Science Technology And Engineering, 2016
Friction stir welding (FSW) is an innovative solid state joining process, developed by The Weldin... more Friction stir welding (FSW) is an innovative solid state joining process, developed by The Welding Institute, UK for joining aluminum, magnesium, zinc and copper alloys. FSW is being used in aerospace, automotive, rail, marine industries, fabrication, etc. FSW is more beneficial over traditional welding process, particularly in the areas of weld quality and environmental impacts. The FSW process parameters such as tool rotation and transverse speed, tool design, axial force, play a major role in deciding the weld quality. In this article, we are going to analyze joining of two same materials by varying affecting parameters and to carry out the optimized set of parameters, which will give high strength for particular pair of dissimilar materials. An attempt has been made to join aluminum alloy 6351 T6 plate having dimension of 120*50*12 with three different featured conical tool friction stir welding (FSW). FSW is more eco-friendly and refine process which give higher joint efficienc...
Friction stir welding (FSW) is an innovative solid state joining process, developed by The Weldin... more Friction stir welding (FSW) is an innovative solid state joining process, developed by The Welding Institute, UK for joining aluminum, magnesium, zinc and copper alloys. FSW is being used in aerospace, automotive, rail, marine industries, fabrication, etc. FSW is more beneficial over traditional welding process, particularly in the areas of weld quality and environmental impacts. The FSW process parameters such as tool rotation and transverse speed, tool design, axial force, play a major role in deciding the weld quality. In this article, we are going to analyze joining of two same materials by varying affecting parameters and to carry out the optimized set of parameters, which will give high strength for particular pair of dissimilar materials. An attempt has been made to join aluminum alloy 6351 T6 plate having dimension of 120*50*12 with three different featured conical tool friction stir welding (FSW). FSW is more eco-friendly and refine process which give higher joint efficiency than fusion welding process if proper parametric is used. Process parameter like Rotational speed, welding speed, Fixture design, Tool Design, Tool Pin are studied in this research work. Welding speed or transverse speed, Range of RPM and tool features are chosen for Experimental work. Check the fatigue test on different range, speed and conical tool using the welding process and check the fatigue life of weld specimen.
International Journal of Engineering studies, 2012
A New element is introduced for FEA family in this article. Studies have been done on different g... more A New element is introduced for FEA family in this article. Studies have been done on different geometries and development of new hexagon shaped element has been done. Hexagon geometry can work well for isotropic materials. Implementation of Hexagon shaped element can give us response for 6 vertices and 6 edges. Here derivation of shape functions has been done and generation of stiffness matrix has been done. A code has been developed in MATLAB for plane stress response of 6-Node Hexagon element. The performance of new element has been compared with analytical results and implementation in physical system has been done.
International Journal of Science Technology & Engineering, 2016
Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new join... more Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new joining technique. Especially high strength aluminium alloys can be welded with large advantages as compared to conventional fusion welding processes. Friction stir welding (FSW) of aluminium components using both fixed and variable gap bobbin tools has been demonstrated by several researchers, and reportedly these procedures were relatively easy to develop. Bobbin welds do not have an initial phase where the welding tool probe is plunged axially into the work piece as is done in conventional FSW. Bobbin welds are typically started by driving onto the edge of the plate or from a pre-drilled hole with an initially slow travel speed until plastic deformation starts, followed by acceleration of the travel speed to the final steady state value. The objective of current paper is to examine and summarize information for change in mechanical properties for bobbin tool friction stir welding (FSW) for joining materials. The findings presented, friction stir welding (FSW) with bobbin tool and parameter involved in it understand.
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2017
The metal joining processes have been evolved a lot. Various techniques have been introduced to o... more The metal joining processes have been evolved a lot. Various techniques have been introduced to observe and evaluate the in-depth study of various welding techniques. Friction stir welding process is one of the well accepted solid state joining process. This research paper represents attempts and experiments made to do 13 mm thick plate friction stir weld with the help of simple vertical milling machine. The experimental procedure followed was bi directional multi pass FSW. The distortion of plate is common phenomena in welding but evolution of distortion while conducting solid state welding process is also interesting observation. The distorted plate leads to failure of component considering loading cycles which are concerned with the weld plate. The distortion studies have been conducted using Vernier height gauge and plate clamping consideration with reference plate and slip gauge.
International Journal of Creative Research Thoughts (IJCRT), 2017
Friction stir weld ing process have been well accepted in the field of Weld ing. While perfo rmin... more Friction stir weld ing process have been well accepted in the field of Weld ing. While perfo rming FSW on experimental basis the plate size considered is 100 x 100 x T, here T is thickness of plate. The facts found while designing and experimenting were interesting. The development phase have given exposure to points which have not been considered while constructing fixtures for holding plates while carrying experimentations. The effects found on plate while changing paramet ers have also changes the results. Here design have been trialed for various experiments and on basis of practical understanding of problem physics one design have been finalized for further experimentations. Experimentations have been carried and with Multiphysics problem have been solved. On basis of practical and Multiphysics data design have been presented. IndexTerms-Fixture; FSW Fixture; load cell fixture FSW, 3axis tool dynamometer for FSW. ______________________________________________________ __________________________________________________ I. INTRO DUCTION FSW have been trialed by various scientists to gain various quality welds in different ferrous and nonferrous materials. Here standard procedure suggests to clamp a plates on milling machine bad or they clamp it by mechanical means like holding clamps. To design FSW fixture study have been carried on basis of experiments with sensor systems and load cells. Here design and development is presented with understanding of problem physics. FSW physics. FSW is process which needs less resources as compared to other welding processes. The design of fixture involves trial testing to gain data for loading during plunge, dwell, feed and retrieval of tool from plate. The temperature of weld plate have also been measured before, during and after weld. The FSW represe nts multiple physics at same time. It starts with frictional heat addition in plate while plunge. At same time stirring of base material occurs. Here the load developed within plate and tool tries to move plates in vertical downward direction, lateral direction and moving advancing side as well retrieving side plates. The forces will further develop onswitching on feed. The heat due to friction increases rapidly. The material available at region of plunge and tool travel path get plasticized and getting stirred in the region with change in its grain size as well in microstructure. Different phases have been developed which are stir zone, Heat effected zone, TMAZ, Base material. Heat is generated and dissipated through the material plate as well through the fixture base plate and other constructions.
International Journal of Advances in Engineering, Science and Technology, 2012
A new element is introduced for FEA family in this paper. Different geometries have different res... more A new element is introduced for FEA family in this paper. Different geometries have different response in physical world when implemented in FEA solver. Here development of new hexagon shaped element is introduced. Hexagon geometry can work well for isotropic materials. Hexagon shaped element can give us response for 6 vertices and 6 edges. A hexagon shaped element is more effective as compared to tria or quard element for isotropic material. To check this shape functions are formulated from geometry. A code is generated in MATLAB for plane stress response of 6-Node Hexagon element. This code contains stiffness matrix formulation, deflection formulation. The developed element responds with change in thickness. The performance of new element has been compared with analytical results. The behaviour from given element is same as behaviour of any beam structure or not is checked in same physics and it also contains same formulation which is required in FEA solver. KEY WORDS: 6 node Hexagon element, hexagon finite Element, Plane stress element in FEA, Hexagon element. Introduction:
IJTSRD, 2018
Friction stir welding is the process which have famous from last 2 decades. The experiments carri... more Friction stir welding is the process which have famous from last 2 decades. The experiments carried are presented in bulk and no significant method is present to make the researcher understand what exactly the experiment was. For understanding the experiment a researcher must have to go through th article thoroughly and then observe and understand various data of experiment like the tooling, plate mounting as well other welding criteria. So the presentation of information is not in proper significant manner. Here an attempt have been made to make learner, researcher as well the experts to make them understand symbolic presentation of experiments mentioning all data related to it. One should have to go through a small exercise to understand it for 1 time then easily one can adopt understanding a same.
elsevier, 2017
Friction Stir Welding is a solid-state joining process of two similar or dissimilar materials. Th... more Friction Stir Welding is a solid-state joining process of two similar or dissimilar materials. The dissimilar joining of aluminum alloy Al6061 and Al5083 with the plates of 6 mm thickness was carried out by friction stir welding. The objective of this research is to enhance the mechanical properties by changing the advancing side material during welding and also optimizing the various process parameters such as tool rotation speed and traverse feed for higher joining strength. The influence of welding process parameters on strength of joint has been evaluated by means of tensile test. The tool rotational speeds were taken between 500 to 1000 rpm and tool traverse speeds were taken between 40 to 125 mm/min. The maximum tensile strength yielded 98.90 MPa when the Al6061 keep in a advancing side and 32 MPa when Al5083 keep in advancing side during weld joint at 1000 rpm and 50 mm/min. It was observed that the advancing sides of materials also play a key role for joint strength while keeping remaining process parameters constant during FSW.
A new element is introduced for FEA family in this paper. Different geometries have different res... more A new element is introduced for FEA family in this paper. Different geometries have different response
in physical world when implemented in FEA solver. Here development of new hexagon shaped element
is introduced. Hexagon geometry can work well for isotropic materials. Hexagon shaped element can
give us response for 6 vertices and 6 edges. A hexagon shaped element is more effective as compared to
tria or quard element for isotropic material. To check this shape functions are formulated from geometry.
A code is generated in MATLAB for plane stress response of 6-Node Hexagon element. This code
contains stiffness matrix formulation, deflection formulation. The developed element responds with
change in thickness. The performance of new element has been compared with analytical results.
The behaviour from given element is same as behaviour of any beam structure or not is checked in same
physics and it also contains same formulation which is required in FEA solver.
KEY WORDS: 6 node Hexagon element, hexagon finite Element, Plane stress element in FEA, Hexagon
element.
Abstract— Friction stir welding (FSW) is a new innovative solid state joining technique for joini... more Abstract— Friction stir welding (FSW) is a new innovative solid state joining technique for joining similar and dissimilar metal which has been used in aerospace, rail, automotive and marine industries. The aim of this project is to optimize the effect of the tool shape and welding parameter on 10 mm thick AA6351 aluminums plates. The process parameters are optimized by using the TAGUCHI METHOD based on L9 orthogonal array. Experiments have been conducted based on three process parameters, namely, the tool rotation rate(rpm), welding speed and tool pin angle at three different levels. Impact Strength has been predicted for the optimum welding parameters and their percentage of contribution in producing a better joint is calculated.
Key words: Friction Stir Welding, Aa6351, Welding Parameter, Impact Strength, Signal-To Noise Ratio
International Journal For Science Technology And Engineering, 2016
Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new join... more Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new joining technique. Especially high strength aluminium alloys can be welded with large advantages as compared to conventional fusion welding processes. Friction stir welding (FSW) of aluminium components using both fixed and variable gap bobbin tools has been demonstrated by several researchers, and reportedly these procedures were relatively easy to develop. Bobbin welds do not have an initial phase where the welding tool probe is plunged axially into the work piece as is done in conventional FSW. Bobbin welds are typically started by driving onto the edge of the plate or from a pre-drilled hole with an initially slow travel speed until plastic deformation starts, followed by acceleration of the travel speed to the final steady state value. The objective of current paper is to examine and summarize information for change in mechanical properties for bobbin tool friction stir welding (FSW) fo...
Materials Today: Proceedings, 2020
International Journal for Research in Applied Science and Engineering Technology, Sep 30, 2017
International Journal of Trend in Scientific Research and Development, 2018
INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY, 2023
Friction stirs processing (FSP) is a method of changing the properties of metal through intense, ... more Friction stirs processing (FSP) is a method of changing the properties of metal through intense, localized deformation. Where Friction Stir Welding (FSW) is Mechanical joining properties are dramatically pushed into deterioration when a tunnel defect is formed. FST is effect found due to regulated heat input and regulated material flow. Sometimes defects in the weld are generated applying certain variations in welding parameters. In this study, the tunnel formation in AA 3102 was experimentally studied by taking various parameter incorporating speed and feed. The effect of tunnel formation was evaluated by Radiography test. Here we are creating the tunnel through the length and which dimension can be control by tool geometry, spindle speed, and feed rate. This experimental investigation covers methodology to enhance the word "defect" to "tunnelling effect" which is created by changing some parameter during processing and welding.
1ME scholar, Mechanical Department, LDRP-ITR, Gandhinagar, India 2Profesor, Mechanical Department... more 1ME scholar, Mechanical Department, LDRP-ITR, Gandhinagar, India 2Profesor, Mechanical Department, LDRP-ITR, Gandhinagar, India ---------------------------------------------------------------------***--------------------------------------------------------------------Abstract Friction stir welding and friction stir spot welding are newly evolved solid state joining processes. These techniques are energy efficient, economical, better than conventional welding processes, and versatile. FSW and FSSW are promising and found to be the very important progression in metal joining area. In this review paper, the basic processes and their various parameters are included for understanding of the FSW and FSSW. While most of the information is related to Aluminium and magnesium alloys, important results are also available for other metal and alloys. At this scenario, technology advancement has growing faster and outpaced the fundamental need to just join the materials and their microstructural ...
International Journal For Science Technology And Engineering, 2016
Friction stir welding (FSW) is an innovative solid state joining process, developed by The Weldin... more Friction stir welding (FSW) is an innovative solid state joining process, developed by The Welding Institute, UK for joining aluminum, magnesium, zinc and copper alloys. FSW is being used in aerospace, automotive, rail, marine industries, fabrication, etc. FSW is more beneficial over traditional welding process, particularly in the areas of weld quality and environmental impacts. The FSW process parameters such as tool rotation and transverse speed, tool design, axial force, play a major role in deciding the weld quality. In this article, we are going to analyze joining of two same materials by varying affecting parameters and to carry out the optimized set of parameters, which will give high strength for particular pair of dissimilar materials. An attempt has been made to join aluminum alloy 6351 T6 plate having dimension of 120*50*12 with three different featured conical tool friction stir welding (FSW). FSW is more eco-friendly and refine process which give higher joint efficienc...
Friction stir welding (FSW) is an innovative solid state joining process, developed by The Weldin... more Friction stir welding (FSW) is an innovative solid state joining process, developed by The Welding Institute, UK for joining aluminum, magnesium, zinc and copper alloys. FSW is being used in aerospace, automotive, rail, marine industries, fabrication, etc. FSW is more beneficial over traditional welding process, particularly in the areas of weld quality and environmental impacts. The FSW process parameters such as tool rotation and transverse speed, tool design, axial force, play a major role in deciding the weld quality. In this article, we are going to analyze joining of two same materials by varying affecting parameters and to carry out the optimized set of parameters, which will give high strength for particular pair of dissimilar materials. An attempt has been made to join aluminum alloy 6351 T6 plate having dimension of 120*50*12 with three different featured conical tool friction stir welding (FSW). FSW is more eco-friendly and refine process which give higher joint efficiency than fusion welding process if proper parametric is used. Process parameter like Rotational speed, welding speed, Fixture design, Tool Design, Tool Pin are studied in this research work. Welding speed or transverse speed, Range of RPM and tool features are chosen for Experimental work. Check the fatigue test on different range, speed and conical tool using the welding process and check the fatigue life of weld specimen.
International Journal of Engineering studies, 2012
A New element is introduced for FEA family in this article. Studies have been done on different g... more A New element is introduced for FEA family in this article. Studies have been done on different geometries and development of new hexagon shaped element has been done. Hexagon geometry can work well for isotropic materials. Implementation of Hexagon shaped element can give us response for 6 vertices and 6 edges. Here derivation of shape functions has been done and generation of stiffness matrix has been done. A code has been developed in MATLAB for plane stress response of 6-Node Hexagon element. The performance of new element has been compared with analytical results and implementation in physical system has been done.
International Journal of Science Technology & Engineering, 2016
Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new join... more Over the last twenty years Friction Stir Welding (FSW) has proven to be a very promising new joining technique. Especially high strength aluminium alloys can be welded with large advantages as compared to conventional fusion welding processes. Friction stir welding (FSW) of aluminium components using both fixed and variable gap bobbin tools has been demonstrated by several researchers, and reportedly these procedures were relatively easy to develop. Bobbin welds do not have an initial phase where the welding tool probe is plunged axially into the work piece as is done in conventional FSW. Bobbin welds are typically started by driving onto the edge of the plate or from a pre-drilled hole with an initially slow travel speed until plastic deformation starts, followed by acceleration of the travel speed to the final steady state value. The objective of current paper is to examine and summarize information for change in mechanical properties for bobbin tool friction stir welding (FSW) for joining materials. The findings presented, friction stir welding (FSW) with bobbin tool and parameter involved in it understand.
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2017
The metal joining processes have been evolved a lot. Various techniques have been introduced to o... more The metal joining processes have been evolved a lot. Various techniques have been introduced to observe and evaluate the in-depth study of various welding techniques. Friction stir welding process is one of the well accepted solid state joining process. This research paper represents attempts and experiments made to do 13 mm thick plate friction stir weld with the help of simple vertical milling machine. The experimental procedure followed was bi directional multi pass FSW. The distortion of plate is common phenomena in welding but evolution of distortion while conducting solid state welding process is also interesting observation. The distorted plate leads to failure of component considering loading cycles which are concerned with the weld plate. The distortion studies have been conducted using Vernier height gauge and plate clamping consideration with reference plate and slip gauge.
International Journal of Creative Research Thoughts (IJCRT), 2017
Friction stir weld ing process have been well accepted in the field of Weld ing. While perfo rmin... more Friction stir weld ing process have been well accepted in the field of Weld ing. While perfo rming FSW on experimental basis the plate size considered is 100 x 100 x T, here T is thickness of plate. The facts found while designing and experimenting were interesting. The development phase have given exposure to points which have not been considered while constructing fixtures for holding plates while carrying experimentations. The effects found on plate while changing paramet ers have also changes the results. Here design have been trialed for various experiments and on basis of practical understanding of problem physics one design have been finalized for further experimentations. Experimentations have been carried and with Multiphysics problem have been solved. On basis of practical and Multiphysics data design have been presented. IndexTerms-Fixture; FSW Fixture; load cell fixture FSW, 3axis tool dynamometer for FSW. ______________________________________________________ __________________________________________________ I. INTRO DUCTION FSW have been trialed by various scientists to gain various quality welds in different ferrous and nonferrous materials. Here standard procedure suggests to clamp a plates on milling machine bad or they clamp it by mechanical means like holding clamps. To design FSW fixture study have been carried on basis of experiments with sensor systems and load cells. Here design and development is presented with understanding of problem physics. FSW physics. FSW is process which needs less resources as compared to other welding processes. The design of fixture involves trial testing to gain data for loading during plunge, dwell, feed and retrieval of tool from plate. The temperature of weld plate have also been measured before, during and after weld. The FSW represe nts multiple physics at same time. It starts with frictional heat addition in plate while plunge. At same time stirring of base material occurs. Here the load developed within plate and tool tries to move plates in vertical downward direction, lateral direction and moving advancing side as well retrieving side plates. The forces will further develop onswitching on feed. The heat due to friction increases rapidly. The material available at region of plunge and tool travel path get plasticized and getting stirred in the region with change in its grain size as well in microstructure. Different phases have been developed which are stir zone, Heat effected zone, TMAZ, Base material. Heat is generated and dissipated through the material plate as well through the fixture base plate and other constructions.
International Journal of Advances in Engineering, Science and Technology, 2012
A new element is introduced for FEA family in this paper. Different geometries have different res... more A new element is introduced for FEA family in this paper. Different geometries have different response in physical world when implemented in FEA solver. Here development of new hexagon shaped element is introduced. Hexagon geometry can work well for isotropic materials. Hexagon shaped element can give us response for 6 vertices and 6 edges. A hexagon shaped element is more effective as compared to tria or quard element for isotropic material. To check this shape functions are formulated from geometry. A code is generated in MATLAB for plane stress response of 6-Node Hexagon element. This code contains stiffness matrix formulation, deflection formulation. The developed element responds with change in thickness. The performance of new element has been compared with analytical results. The behaviour from given element is same as behaviour of any beam structure or not is checked in same physics and it also contains same formulation which is required in FEA solver. KEY WORDS: 6 node Hexagon element, hexagon finite Element, Plane stress element in FEA, Hexagon element. Introduction:
IJTSRD, 2018
Friction stir welding is the process which have famous from last 2 decades. The experiments carri... more Friction stir welding is the process which have famous from last 2 decades. The experiments carried are presented in bulk and no significant method is present to make the researcher understand what exactly the experiment was. For understanding the experiment a researcher must have to go through th article thoroughly and then observe and understand various data of experiment like the tooling, plate mounting as well other welding criteria. So the presentation of information is not in proper significant manner. Here an attempt have been made to make learner, researcher as well the experts to make them understand symbolic presentation of experiments mentioning all data related to it. One should have to go through a small exercise to understand it for 1 time then easily one can adopt understanding a same.
elsevier, 2017
Friction Stir Welding is a solid-state joining process of two similar or dissimilar materials. Th... more Friction Stir Welding is a solid-state joining process of two similar or dissimilar materials. The dissimilar joining of aluminum alloy Al6061 and Al5083 with the plates of 6 mm thickness was carried out by friction stir welding. The objective of this research is to enhance the mechanical properties by changing the advancing side material during welding and also optimizing the various process parameters such as tool rotation speed and traverse feed for higher joining strength. The influence of welding process parameters on strength of joint has been evaluated by means of tensile test. The tool rotational speeds were taken between 500 to 1000 rpm and tool traverse speeds were taken between 40 to 125 mm/min. The maximum tensile strength yielded 98.90 MPa when the Al6061 keep in a advancing side and 32 MPa when Al5083 keep in advancing side during weld joint at 1000 rpm and 50 mm/min. It was observed that the advancing sides of materials also play a key role for joint strength while keeping remaining process parameters constant during FSW.
A new element is introduced for FEA family in this paper. Different geometries have different res... more A new element is introduced for FEA family in this paper. Different geometries have different response
in physical world when implemented in FEA solver. Here development of new hexagon shaped element
is introduced. Hexagon geometry can work well for isotropic materials. Hexagon shaped element can
give us response for 6 vertices and 6 edges. A hexagon shaped element is more effective as compared to
tria or quard element for isotropic material. To check this shape functions are formulated from geometry.
A code is generated in MATLAB for plane stress response of 6-Node Hexagon element. This code
contains stiffness matrix formulation, deflection formulation. The developed element responds with
change in thickness. The performance of new element has been compared with analytical results.
The behaviour from given element is same as behaviour of any beam structure or not is checked in same
physics and it also contains same formulation which is required in FEA solver.
KEY WORDS: 6 node Hexagon element, hexagon finite Element, Plane stress element in FEA, Hexagon
element.
Abstract— Friction stir welding (FSW) is a new innovative solid state joining technique for joini... more Abstract— Friction stir welding (FSW) is a new innovative solid state joining technique for joining similar and dissimilar metal which has been used in aerospace, rail, automotive and marine industries. The aim of this project is to optimize the effect of the tool shape and welding parameter on 10 mm thick AA6351 aluminums plates. The process parameters are optimized by using the TAGUCHI METHOD based on L9 orthogonal array. Experiments have been conducted based on three process parameters, namely, the tool rotation rate(rpm), welding speed and tool pin angle at three different levels. Impact Strength has been predicted for the optimum welding parameters and their percentage of contribution in producing a better joint is calculated.
Key words: Friction Stir Welding, Aa6351, Welding Parameter, Impact Strength, Signal-To Noise Ratio