International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 2, March - April (2013), pp. 245-253 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

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COMPARATIVE STUDY ON DIFFERENT PIN GEOMETRIES OF TOOL PROFILE IN FRICTION STIR WELDING USING ARTIFICIAL NEURAL NETWORKS
D. Kanakaraja 1, P. Hema 2, K. Ravindranath 3 PG Student 2 Assistant professor 3 Professor Mechanical Engineering Department, Sri Venkateswara College of Engineering, S.V.University, Tirupati, Andhra pradesh- 517502, India
1

ABSTRACT Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in aerospace, rail, automotive and marine industries for joining aluminium, magnesium, zinc and copper alloys. The FSW process parameters such as tool rotational speed, welding speed, axial force etc., play a major role in deciding the weld quality. The present work is a comparitive study on different pin geometries of FSW tool using ANN in MATLAB. This work focuses on two methods such as Artificial neural networks and Regression analysis to predict the tensile strength of friction stir welded 6061 aluminium alloy. An artificial neural network (ANN) model was developed for the analysis of the friction stir welding parameters of AA6061 plates. The Tensile strength of weld joints were predicted by taking the parameters Tool rotation speed, Weld speed and Axial force as a function. A comparison was made between measured and predicted data. A regression model is also developed and the values obtained for the response Tensile strengths are compared with measured values. The graphs were plotted between Regression predicted values and Experimental data to show the accuracy of experimental results. It was found that among these methods ANN model is easier and effective methodology in order to find out the performance output and welding conditions. Key words: Friction stir welding, Aluminium alloy, Tensile Strength, Artificial neural networks, Regression analysis

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

I. INTRODUCTION Friction stir welding (FSW) is a solid state method developed by the welding institute (TWI) (Thomas, 1991) and now being increasingly used in the welding of aluminum. Aluminum alloys find wide applications in aerospace, automobile industries, in ship building, in train wagons and trams, in offshore structures and in bridge constructions due to its light weight and higher strength to weight ratio (Dawes, 1995). FSW is a innovative solid phase welding process in which there is no melting of the material [1]. Hence, FSW is preferred over the commonly used fusion welding techniques for the advantages such as: there are no voids and cracking in the weld, there is no distortion of the work piece, no need of filler materials, no costly weld preparation required, no shielding gas is required during FSW process (Thomas et al., 1997). It is a clean and environment friendly process because there are no harmful effects like arc formation, radiation, release of toxic gas etc. FSW is perhaps the most remarkable and potentially useful welding technique. However, during FSW process using inappropriate welding parameters can cause defects in the joint and deteriorate the mechanical properties of the FSW joints (Cavaliere et al., 2008). Although FSW consistently gives high quality welds, proper use of the process and control of number of parameters is needed to achieve this. To produce the best weld quality, theses parameters have to be determined individually for each new component and alloy (Wei et al., 2007). The quality of friction stir welded joint is controlled by three welding parameters, these are Tools Rotation Speed, Welding Speed and Axial Force. In FSW a rotating tool moves along the joint interface, generating heat and resulting in a re-circulating flow of plasticized material near the tool surface [2-5]. This plasticized material is subjected to extrusion by the tool pin rotational and traverse movements leading to the formation of the so called stir zone. The formation of the stir zone is affected by the material flow behavior under the action of the rotating tool. The FSW process is applied presently for welding aluminum and magnesium alloys as well as copper, steel, composites and dissimilar materials [6-10]. Welding of aluminum alloy especially heat treatable wrought aluminum alloy of AA6XXX aluminum by FSW produces better quality [11]. II. PLAN OF INVESTIGATION This investigation was planned to be carried out in following steps (i) Identifying the important process parameter and finding the range of process parameter such as tool rotational speed, welding speed and Axial force. (ii) Collection of experimental data. (iii) Developing of Regression model (Developing mathematical model and checking the adequacy) and predict the Tensile strength as the function of input parameters. (iv) Developing ANN model, Training and Testing of Neural Network to predict the Tensile Strength values. (v) Comparing and concluding about different pin profiles. The important processes parameters (Tool rotational speed, welding speed, Axial force) and tool probe (pin) geometry were identified based on series of trials and authors earlier study. Parameters such a way that the friction stirred welded joint should be free from any visible external defect. The selected process parameters with their levels are given in Table 1. The experiment was based on three factors with three levels of full factorial experimental design. As prescribed in the Experimental design matrix twenty seven joints were carried out using Two different probe geometry by considering three levels of process parameter, namely tool rotational speed and welding speed as given in the Table 2. It is to be
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

further noted that the experiments were conducted with a constant tool rotational speed, welding speed and axial load for two pin profiles. Table 1: Process parameters and their levels taken for AA6061 material Level Tool speed (rpm) 1 1200 2 1600 3 2000 Welding speed (mm/min) 48 60 72 Axial force (K.N) 1.5 2.0 2.5

Table 2 Experimental design matrix and results

Coded value Trial no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 N 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 S 1 1 1 2 2 2 3 3 3 1 1 1 2 2 2 3 3 3 1 1 1 2 2 2 3 3 3 F 1 1 1 2 2 2 3 3 3 2 2 2 3 3 3 1 1 1 3 3 3 1 1 1 2 2 2 Tool speed (rpm) 1200 1200 1200 1200 1200 1200 1200 1200 1200 1600 1600 1600 1600 1600 1600 1600 1600 1600 2000 2000 2000 2000 2000 2000 2000 2000 2000 Real value Welding speed (mm/min) 48 48 48 60 60 60 72 72 72 48 48 48 60 60 60 72 72 72 48 48 48 60 60 60 72 72 72 Axial force(K.N ) 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 1.5 2 2.5 Tensile strength (N/mm2) For For Triangular Conical pin pin 61.4 113.39 66.7 172.47 40.5 171.11 58.3 187.36 45.3 101.28 38.8 168.08 64.6 129.77 65.3 44.61 40.8 153.19 59.6 142.25 75 184.14 79.5 156.46 60.7 181.92 65.3 156.77 62.9 120.43 65.6 175.49 62.7 135.82 75.6 88.92 97.8 127.11 86.2 91.82 75.57 129.27 86.08 137.86 73.8 119.45 85.71 108.88 90.22 109.25 89.5 124.76 88.3 89.72

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

III. PREDICTION OF TENSILE STRENGTH

A. Development of mathematical model by Regression analysis

Tensile strength of the joints is the function of rotational speed, welding speed, and axial force and it can be expressed as Y = f (N, S, F) ---------(1)

Where Y-The response, N- Rotational speed (rpm), S- Welding Speed (mm/s) , F - Axial Force (tones). For the three factors, the selected polynomial (regression) could be expressed as Y = k+ aN + bS + cF ----------(2)

Where k is the free term of the regression equation, the coefficients a, b, and c are linear terms Table 3: Estimated regression coefficients of mathematical models Regression coefficients K A B C Tensile Strength N/mm2 For Conical Pin -2.65 0.961 -0.014 -0.232 For Triangular Pin 8.83 -0.197 -0.581 -0.228

MINITAB 15 Software Packages is used to calculate the values of those coefficients for different responses and is presented in Table 3. After determining the coefficients, the mathematical models are developed. The developed final mathematical model equations in the coded form are given below: For Conical pin profile Tensile strength = - 2.65 + 0.961 (N) - 0.014 (S) - 0.232(F) For Triangular pin profile Tensile strength = 8.83 - 0.197 (N) - 0.581 (S) - 0.228 (F) ----------(4) --------- (3)

The validity of regression models developed is tested by drawing scatter diagrams. Typical scatter diagrams for all the models are presented in Figures 6 and 7. The observed values and predicted values of the responses are scattered close to the 45 line, indicating an almost perfect fit of the developed empirical models [12]

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110

200 180

Regression predicted T.S values

90

70

Regression predicted T.S values

160 140 120 100 80 60 40 40 60 80 100 120 140 160 180 200
Experimental T.S values

50

30 30 50 70 90
Experimental T.S values

Figure 2: Scatter diagram for conical pin

B. Artificial Neural Network (ANN)

Figure 3: Scatter digram for Triangular pin

ANNs are computational models, which replicate the function of a biological network, composed of neurons and are used to solve complex functions in various applications. Neural networks consist of simple synchronous processing elements that are inspired by the biological nerve systems. The basic unit in the ANN is the neuron. Neurons are connected to each other by links known as synapses; associated with each synapse there is a weight factor. Details on the neural network modeling approach are given in elsewhere[13]. One of the most popular learning algorithms is the back-propagation (BP) algorithm. In this present study, BP algorithm is used with a single hidden layer improved with numerical optimization techniques called Levenberg Marquardt (LM) [14]. The architecture of ANN used in this study is 3-20 -1, 3 corresponding to the input values, 20 to the number of hidden layer neurons and 1 to the output. The topology architecture of feed-forward three-layered back propagation neural network is illustrated in Figure 4 below.

Figure 4: Architecture of feed forward three layered back propagation neural network

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

MATLAB 7.1 has been used for training the network model for tensile strength prediction. The training parameters used in this investigation are shown in Table.5 The neural network described in this paper, after successful training, will be used to predict the tensile strength of friction stir welded joints of 6061 aluminium alloy within the trained range. Table 4: Training parameters used in ANN Number of input nodes Number of hidden nodes Number of output nodes Learning rule Number of epochs Mu 3 20 1 Levenburg marquatt 5000 0.01

IV. ANN RESULTS The results obtained after training and testing of Artificial Neural Networks are shown in the tables below Table 5: Test conditions at different hidden neurons (TS) for Conical pin profile
Predicted Tensile Strength N/mm2

Tool speed (rpm)

Welding speed
(mm/min)

Axial force (KN)

Exp. Value N/mm2

@ 20N

DEV

@25N

DEV

@30N

DEV

@35N

DEV

1200 1200 1200 1600 1600 2000 2000

48 60 72 48 60 48 60

2.5 2.5 2.5 1.5 1.5 2.5 2

40.5 38.8 40.8 59.6 60.7 75.57 73.8

64.19 71.46 78.16 73.38 72.84 86.58 89.02 55.68

-0.585 -0.842 -0.916 -0.231 -0.200 -0.146 -0.206 76.51

65.01 42.62 55.63 85.22 69.09 89.72 89.09 -0.447

-0.605 -0.098 -0.363 -0.430 -0.138 -0.187 -0.207 70.91

60.62 59.85 66.82 72.85 65.25 87.91 87.66 -0.290

-0.497 -0.543 -0.638 -0.222 -0.075 -0.163 -0.188 71.56

48.08 58.08 64.95 64.38 64.94 78.15 86.15 -0.332

-0.187 -0.497 -0.592 -0.080 -0.070 -0.034 -0.167 66.39

AVERAGES

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Table 6: Test conditions at different hidden neurons (TS) for Triangular pin profile
Tool spee d
(rpm)

Welding speed (mm/min)

Axial force (KN)

Exp. Value
N/mm2

Predicted Tensile Strength N/mm2 @ 20N DEV @25N DEV @30N DEV @35N DEV

1200 1200 1600 1600 2000 2000 2000

60 72 60 72 48 60 72

2 2 2.5 2.5 2 2.5 2.5

101.28 44.61 120.43 88.92 91.82 108.88 89.72

174.76 141.48 155.83 134.76 125.23 124.91 126.26 92.23

-0.726 -2.171 -0.294 -0.516 -0.364 -0.147 -0.407 140.46

170.96 143.12 119.1 173.64 137.34 119.6 118.49 -0.661

-0.688 -2.208 0.011 -0.953 -0.496 -0.098 -0.321 140.32

152.03 143.03 138.34 134.74 124.31 126.25 131.78 -0.679

-0.501 -2.206 -0.149 -0.515 -0.354 -0.160 -0.469 135.78

140.22 125.42 131.54 90.83 119.23 115.57 118.68 -0.622

-0.384 -1.811 -0.092 -0.021 -0.299 -0.061 -0.323 120.21

AVERAGES

Comparison of Conical pin and Triangular pin profile tools

Figure 5: Conical pin profile vs Triangular pin profile experimental T.S values(N/mm2) From the above plot it is observed that Triangular pin profile tool is better than conical pin profile tool which yields more (2 times) Tensile strength.

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VI CONCLUSIONS This paper has describes two models for Predicting the Tensile strength of friction stir welded AA6061 aluminium alloy using Regression analysis and Artificial Neural Network(ANN). From this investigation, the following important conclusions are derived. 1) a regression model is developed and the values obtained for the response strengths are compared with measured values. it shows that the models are adequate without any violation of independence or constant assumption. 2) ANN model has been developed for prediction of strength as a function of welding parameters. The model has been proved to be successful in terms of agreement with experimental results. The proposed model can be used in optimization of welding process for efficient and economic production by forecasting the strength in welding operations. 3) The results that are obtained for the response Tensile strength in ANN model and Regression analysis are compared with experimental data. Among these methods ANN model is easier and effective methodology in order to find out the performance output and welding conditions. 4) Finally it is observed that Triangular pin profile is better than Conical pin profile because the obtained tensile strength values are higher for Friction stir welded joint. REFERENCES 1. Ratnesh K. Shukla and Pravin K. Shah, Comparative study of friction stir welding and tungsten inert gas welding process Indian Journal of Science and Technology Vol. 3 No. 6 (June 2010) ISSN: 0974- 6846 R. Nandan, T. DebRoy and H. K. D. H. Bhadeshia, Recent advances in friction stir weldingprocess, weldment structure and properties, Progress in Materials Science, vol.53, 980-1023, (2008) W. M. Thomas, E. D. Nicholas, J. C. Needham, M. G. Murch, P. Temple- Smith and C. J. Dawes, Friction stir butt welding, International Patent Application No. PCT/GB92/ 02203, December 1991. C. J. Dawes and W. M. Thomas, Friction stir process welds aluminum alloys, Welding Journal 75, 41-44, (1996). Jae-Hyung Cho, E. Donald, Boyce and Paul R. Dawson, Modeling strain hardening and texture evolution in friction stir welding of stainless steel, Material Science Engineering A, 398, 146-163. (2005). Kalemba, S. Dymek, C. Hamilton and M. Blicharski, Microstructural investigation of friction stir welded 7136-T76511 aluminium, Proceedings of the 13th International Conference on Electron Microscopy,EM2008, Zakopane, 79 , (2008). H. Uzun, C.D. Donne, A. Argagnotto, T. Ghidini and C. Gambaro, Friction stir welding of dissimilar Al 6013-T4 to X5CrNi18-10 stainless steel, Materials and Design, 26, 4146, (2005). P. Cavaliere, R. Nobile, F. W. Panella and A. Squillance, Mechanical and microstructural behavior of 2024-7075 aluminium alloy sheets joined by friction stir welding, International Journal of Machine Tools and Manufacture, 46, 588-594, (2006).

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