E It

ENGINEERING AND Volume 8 | Issue 1&2 | April & October, 2017 | 1-14 ARTICLE CHRONICLE :
Received : 25.12.16;
TECHNOLOGY e ISSN-2230-9284 | Visit us : www.researchjournal.co.in
Revised : 01.09.17;
IN INDIA DOI : 10.15740/HAS/ETI/8.1&2/1-14 Accepted : 15.09.17

RESEARCH ARTICLE

Comparison of RSM and RA with ANN in predicting

mechanical properties of friction stir welded aluminum
pipes
IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

ABSTRACT
Aluminum can’t successfully be arc welded in an air environment, due to the affinity for oxygen. If fusion welded in normal
atmosphere oxidization readily happens and this outcome in both slag inclusion and porosity in the weld, greatly reducing its
mechanical properties. This work presents a systematic approach to develop the suggestion model by three (ANN), response
surface methodology (RSM) and regression analysis (RA) for predicting the ultimate tensile strength, percentage of elongation
and hardness of 6061 aluminum alloy which is widely used in automotive, aircraft and defense industries by incorporating
(FSW) friction stir welding process parameter such as tool rotation speed, welding speed and material thickness. The results
obtained through regression analysis and response surface methodology were compared with those through artificial neural
networks.
KEY WORDS : Friction stir welding, Aluminium pipe, Regression analysis, Response surface methodology, Artificial
neural network
How to cite this Article : Ibraheem Sabry, Ahmed M. El-Kassas, A.M. Khourshid and H.M. Hindawy, (2017). Comparison of RSM and RA
with ANN in predicting mechanical properties of friction stir welded aluminum pipes. Engg. & Tech. in India, 8 (1&2) : 1-14; DOI : 10.15740/
HAS/ETI/8.1&2/ 1-14.

INTRODUCTION
The aluminium and its alloys are increasingly used in many important manufacturing areas, such as the automobile
industry, aeronautic and military, because of their lowdensity and good mechanical properties, however, the welding of
aluminum and its alloys has always represented a great challenge for designers and technologists (Zhou et al., 2006).
Many difficulties are associated with this kind of joint process. It is obvious that serious problems, such as
tenacious oxide layer cavities, hot cracking sensitivity, and porosity, may occur when fusion welding is applied to
aluminum and its alloys. Moreover, the conventional techniques, such as fusion welding, often lead to significant
strength deterioration in the joint because of a dendritic structure formed in the fusion zone (Su et al., 2003).
The joining of aluminum alloys, especially those which are difficult to weld, has been the initial target for
developing and judging the performance of (FSW). Friction stir welding, a process invented at TWI, Cambridge,
involves the joining of metal without fusion or filler materials. It is used already in aroutine, as critical applications,
for the joining of structural components made of aluminum and its alloys. Indeed, it has been convincingly demonstrated
that the process results in strong and ductile joints, sometimes which in systems have proved difficult using conventional

HIND INSTITUTE OF SCIENCE AND TECHNOLOGY

 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

Table A : Chemical composition (weight %) of Al 6061 aluminum pipe

Weight % Al Si Fe Cu Min Mg Cr Zn Ti
6061 Ball 0.6 0.70 0.2 0.15 0.80 0.33 0.23 0.12

Table B : The mechanical properties of Al 6061 aluminum pipe

Alloy Ultimate tensile strength σ UTS M pa Elongation EL% Hardness VHD
6061 252.690 8 86

welding techniques (Ambrogio et al., 2006; Davies et al., 2005 and Grant et al., 2006). The welds are generated by
the concerted action of frictional heating and mechanical perversion due to the rotating tool. The maximum temperature
amount to is of the order of 0.8 of the melting temperature (Klingensmith et al., 2005).This work constructs a
mathematical model for predicting some mechanical properties of Al 6061 alloy friction stir welded pipe joints. These
properties are the ultimate tensile strength, percentage of elongation and hardness.The model is developed by three
methods: artificial neural networks (ANN) using software, response surface methodology (RSM) and regression
analysis (RA). The model parameters are tool rotational speed, welding speed and material thickness. This work
develops also a cost model to predict the cost of Al 6061 alloy friction stir welded pipe joints based on usual cost
parameters.

EXPERIMENTAL PROCEDURE
Material :
The chemical composition and mechanical properties of Al 6061 aluminum pipe parts used in the present study
as deliveredby the Miser Aluminum company are given in Tables (A-B).

Tool design :
The design of the tool is a critical factor as a good tool can improve both the quality of the weld and the maximum
possible welding speed. It is desirable that the tool material is high carbon steel, sufficiently strong, tough and hardwearing, at
the welding temperature (Zeng et al., 2006). The tool pin penetration depth was suggested to be at least about 90 per cent of the
work piece thickness. We used three tools with flat shoulder, tools was fixed on the axis of friction stir welding pipes. In the
present study the tool length (L) (2,3 and 4 mm), were 50 mm and two different pin length pin diameter (d) 1mm and shoulder
Diameter (D) (10 mm).

Design and constructed :

Setup friction stir welding: constructed apparatus is mounted on the drilling press machine bed to the two workpieces
of the studied materials which will be welded by friction stir welding technique, (Fig. A). Showing illustration, drawing,

Fig. A : Friction stir welding machine

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
2
 COMPARISON OF RSM & RA WITH ANN IN PREDICTING MECHANICAL PROPERTIES OF FRICTION STIR WELDED ALUMINUM PIPES

and construction setup friction stir welding for pipe parts.

Tensile testing :
Tensile testing, also known as tension testing, is a fundamental material science test in which a sample is subjected
to uniaxial tension until failure. The scorefrom the test are commonly used to select a material for an application, for
quality control and to predict how a material will react under other types of forces. Properties that are directly
measured via a tensile test are anultimate tensile strength (UTS), maximum elongation (EL %).

Vickers hardness testing :

The hardness number is determined by the load over the surface area of the indentation and not the area normal
to the force and is, therefore, not a pressure.

EXPERIMENTAL FINDINGS AND ANALYSIS

Visual inspection of the upper (external surface of welded specimens) showed uniform semicircular surface
ripples, caused by the final sweep of the trailing edge of rotating tool shoulder over weld nugget, under the effect of
probe overhead pressure. The presence of such surface ripples, known as onion rings. (Fig. 1 and 2) shows the
surface appearances of the weld the interface between the crystallized nugget zone and the parent metal is relatively
diffuse on the retreating side of the tool, but quite sharp on the advancing side of the tool.

Fig. 1 : Exit pin

Fig. 2 : Finished pipe

Tensile test results :

The quality of the welds was assessed based on tensile tests, Tensile tests were performed on the base metal
and welded specimens, Transverse tensile properties such as tensile strength, the percentage of elongation and joint
efficiency of the FSW joints have been evaluated. At each condition, three specimens are tested and anaverage of
the results of three specimens was measured, it can be inferred that the rotational speed and thickness are having an
influence on tensile properties of the FSW joints show in (Fig. 3-5).
The joints fabricated at high rotational speed (1800rpm) exhibited superior tensile properties compared to other
joints. Similarly, the joints fabricated with high material thickness are showing good tensile properties comparable to
that of a less material thickness see (Fig.6-8).

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
3
 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

tTravel
r a v e l s speed
p e e d 44 m
mm/min
m / m in TTravel
r a v e l sspeed
p eed 8 mm/min
8 m m / m in TTravel
r a v e l sspeed
p e e d 10
1 0 mm/min
m m / m in

2210
10
) 2200
00
a
P
Tensile strength (MPa)
M
( 1190
90
h
t
g 1180
80
n
er
t 1170
70
S
lei 1160
60
s
n
e 1150
50
T
1140
40
4 00 600 800 1000 1200 1400 160 0 18 00 2000
400 600 800 1000 1200 1400 1600 1800 2000
R o t aRotation
t i o n speed
S p e (rpm)
ed (rp m )

Fig. 3 : Relation between ultimate tensile strength and rotational speed of AL 6061 (thickness 2 mm)

t Travel
r a v e l speed
s p e e d4 mm/min
4 m m / m in tTravel
r a v e l speed
s p e e 8
d mm/min
8 m m / m in t Travel
r a v e l sspeed
p e e d101 mm/min
0 m m / m in

1 9199
9
)a
Tensile strength (MPa)

P1 8189 9
M
(h1 7179
tg 9
n
ret 1 6169 9

S
eil 1 5159
9
sn
eT1 4149
9

1 3139
9
4 0400
0 6 0600
0 8 0 0 1 0 0 0 1 1200
2 0 0 1 41400
0 0 1 1600
6 0 0 1 1800
8 0 0 2 2000
0 0 0
800 1000
R o t a t Rotation
i o n Sspeed
p e (rpm)
e d (r p m )

Fig. 4 : Relation between ultimate tensile strength and rotational speed of AL 6061 (thickness 3 mm)

t Travel
r a v e l sspeed
p e e d4 4mm/min
m m / m in t r a Travel
v e l s p speed
e e d 88 mmm/min
m / m in t rTravel
a v e l s speed
p e e d 1 0mm/min
10 m m /m in

2 0200
0
)a
P1 9190
0
Tensile strength (MPa)

(M1 8180
0
th
gn 1 7170
0
er 1 6160
0
tS
lei 1 5150
0
sn 140
eT1 4 0

1
130
3 0
4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0
400 600 800 1000 1200 1400 1600 1800 2000
R o ta tio n S p e e d (r p m )
Rotation speed (rpm)
Fig. 5 : Relation between ultimate tensile strength and rotational speed of AL 6061 (thickness 4 mm)

tTravel
r a v e l speed
s p e e d4 4mm/min
m m /m in tTravel
r a v e l sspeed
p e e d8 8 mm/min
m m / m in tTravel
r a v e l sspeed
p e e d10
1 0mm/min
m m / m in

88
7 7.5
.5
77
Elongation %

% 6 6.5 .5
n 66
iot
ag 5 5.5
.5
n 55
ol 4 4.5
.5
E 4
4
3 3.5
.5
33
4 400
00 6 600
00 8800
1 1000
000 00 11200
200 1 1400
400 11600
6 00 11800
80 0 22000
000

R o t a tRotation
i o n Sspeed
p e (rpm)
ed (rp m )
Fig. 6 : Relation between elongation and rotational speed of AL 6061 (thickness 2 mm)

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
4
 COMPARISON OF RSM & RA WITH ANN IN PREDICTING MECHANICAL PROPERTIES OF FRICTION STIR WELDED ALUMINUM PIPES

t r a v e l speed
Travel s p e e d4 mm/min
4 m m /m in tTravel
r a v e l speed
s p e e d8 8mm/min
m m / m in tTravel
r a v e l speed
s p e e d101 mm/min
0 m m / m in

77

6 6.5
.5

66
Elongation %
%
n 5.5
oi 5 . 5
ta 5 5
g
n 4 4.5
.5
lo
E 44
3 3.5
.5

33
4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0
400 600 800 1000 1200 1400 1600 1800 2000
R o ta tio n S p e e d (r p m )
Rotation speed (rpm)
Fig. 7 : Relation between elongation and rotational speed of AL 6061 (thickness 3 mm)

t Travel
r a v e l speed
s p e e 4
d mm/min
4 m m / m in tTravel
r a v e l speed
s p e e 8
d 8 m m / m
mm/min in tTravel
r a v e l speed
s p e e 10
d 1mm/min
0 m m / m in

6
6
5 5.5
.5
Elongation %

% 55
n
oit
ag 4 4.5
.5
n
ol 4 4
E
3 3.5
.5

33
4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0
400 600 800 1000 1200 1400 1600 1800 2000
R o ta tio n S p e e d (r p m )
Rotation speed (rpm)
Fig. 8 : Relation between elongation and rotational speed of AL 6061 (thickness 4 mm)

t r a v e l speed
Travel sp ee 4
d mm/min
4 m m /m in tTravel
r a v e l speed
s p e e d8 8mm/min
m m / m in tTravel
r a v e l speed
s p e e d101 mm/min
0 m m / m in
880
0

775
5
)
Hardnes (VHD)

D
H 770
0
V
(
se 665
5
n
rd
a
660
0
H 555
5

550
0
4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0
400 600 800 1000 1200 1400 1600 1800 2000
R o t a tRotation
i o n Sspeed
p e (rpm)
e d (r p m )

Fig. 9 : Relation between hardness and rotational speed of AL 6061 (thickness 2 mm)

Travel
t r a v e l sspeed
p e e d 4
4 mm/min
m m / m in Travel speed 8 mm/min
tr a v e l s p e e d 8 m m / m in t r a v e l sspeed
Travel p e e d 10
1 0 mm/min
m m / m in

7 0
70
6 5
) 65
D
H60 6 0
Hardness (VHD)

(V
ss 5 5
e 55
n
d
ra 50
5 0
H
4 5
45
4 0
40
4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0
400 600 800 o t a t i o n 1200
R 1000 1400
S p e e d (r p m ) 1600 1800 2000
Rotation speed (rpm)
Fig. 10 : Relation between hardness and rotational speed of AL 6061 (thickness 3 mm)

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
5
 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

tTravel
r a v e l sspeed
pe e d 4
4 mm/min
m m / m in tTravel
r a v e l s speed
p e e d 88 m m / m in
mm/min tTravel
r a v e l s speed
p e e d 110
0 m m / m in
mm/min
770
0

665
5
)
D660 0
H5 5
Hardness (VHD)

55
(V
ss 550
e 0
n 445
5
d
r
a 440
0
H
335
5

330
0
4 00 60 0 8 0 0 10 00 1 20 0 14 0 0 16 00 1 80 0 20 0 0
400 600 800 1000 1200 1400 1600 1800 2000
R o ta tio n S p e e d (r p m )
Rotation speed (rpm)
Fig. 11 : Relation between hardness and rotational speed of AL 6061 (thickness 4 mm)

Hardness measurement of the joints :

Hardness measurement was taken across the BM, HAZ, and NZ, For FSW specimens it can be inferred that
the decrease in hardness at weld centreline increases by increasing the rotational speed. Such observation could be
understood in the light of relative increasein the degree of plastic deformation an frictional heat generatesat higher
rotational speeds, which effect the dynamic crystallization as well as the dynamic recovery at theTMAZ. In general,
the hardness decreases from the base metal towards the weld centreline show in (Fig. 9-11).

Mathematical modeling :
Regression analysis :
The tensile strength of the joints is the function of rotational speed, welding speed and it can be expressed as:
Y = f (N, T, F)

where,
Y- The response. N- Rotational speed (RPM). T- Material thickness, F – travel speed (mm/min).
For the three factors, the selected polynomial (regression) could be expressed as:
Y = k+ aN + bT + cF

where,
k is the free term of the regression equation, the co-efficients a, b, and c are linear terms (Kanakaraja and Hema,
2013) .
MINITAB 15 software packages are used to calculate the values of these co-efficients for different responses.
After determining the co-efficients, the mathematical models are developed. The developed final mathematical model
equations in the coded form are given below :
Tensile strength = 162 + 0.0364 (N) -7.05 (T) - 1.44 (F)
Elongation % = 4.89 - 0.001 (N) + 0.542 (T) + 0.067 (F)
Hardness (VH) = 62 + 0.0099 (N) - 3. 67 (T) - 0.604 (F).
The validity of regression models developed is tested by drawing scatter diagrams. Typical scatter diagrams for
all the models are presented in Fig. (12-14). The observed values and predicted values of the responses are scattered

Table 1 : Estimated regression co-efficients of mathematical models (Al 6061)

Regression co-efficients Tensile strength Elongation % Hardness
k 162 4.89 62
A 0.036 0.001 0.009
B 7.05 0.542 3.67
C -1.44 -0.067 0.604

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
6
 COMPARISON OF RSM & RA WITH ANN IN PREDICTING MECHANICAL PROPERTIES OF FRICTION STIR WELDED ALUMINUM PIPES

Fig. 12 : Relation between exprimental tensile strength and predicted rensile stregth

Fig. 13 : Relation between exprimental elongation per cent and predicted elongation per cent

Fig. 14 : Relation between exprimental hardness and predictred hardness

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
7
 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

close to the 45° line, indicating an almost perfect fit of the developed empirical models (Plaintively et al., 2011 and
Zhang and Friedrich, 2003).

Response surface methodology :

The 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, T, F)

where,
Y-The response. N- Rotational speed (RPM). T- material thickness, F – travel speed (mm/min).
For the three factors, the selected polynomial (regression) could be expressed as :
Y = K+ aN + bT + cF + a2N2 + b2T2 + c2F2+ + abNT + ac NF +bc TF

where,
k is the free term of the regression equation, the co-efficients a, b, and c is linear terms (Kanakaraja and Hema,
2013; Ramasamy et al., 2002 and Kim et al., 2003).
Design-Expert 6.0.8 software packages is used to calculate the values of these co-efficients for different responses
and is presented in Table 2. After determining the co-efficients, the mathematical models are developed see (Fig.15-
18). The developed final mathematical model equations in the coded form are given below:
Tensile strength(MPa) = 161.03+ 0.03N-7.1 T +0.71F +8.1E-004 N2 -3.3T2 - 0.10F2 -8.3NT-0.2973NF-0.17368TF
Elongation%=3.7+3.4E-003 N-0.62T+0.041F-2.0E-004N2-1.8E-005T2+9.8E-003F2-3E-007NT+0.04NF-8.8E-
003TF
Hardness (VHD)=63.96+0.011N-7.87 T-0.8F-4.0E-003N2-4.06E-004T2+0.15F2-5.1E-006NT-0.4NF - 0.10202TF
Table captions appear cantered the table in upper and lower case letters. When referring to a table in the text, no
abbreviation is used and “table” is capitalized.

Optimization of parameters of FSW on responses :

One of the most substantial objectives of this realization was to maximize the tensile strength ,elongation per cent
and hardness of friction stir welded joints pipes of Al 6061 and also, find the optimum process parameters from the
suggestion model developed. We feel that numerical optimization such describes multiple response methods called
desirability this method used to solve multiple response optimization problems, combines multiple responses into a
dimensionless measure of performance called the overall desirability function. The desirability ranges between 0 and
1. The suggestion model predicted optimal results from above technique are a tensile strength, elongation per cent and
hardness that can be obtained, are 205 Mpa, 7.1 per cent and 69, respectively.The acquired desirability value of 0.766.

Table 2: Estimated regression co-efficients of mathematical models (RSM) (Al 6061)

Regression co-efficients Tensile strength Elongation% Hardness
b0 +116.74726 +3.79137 +63.96119
b1 0.038318 +3.499E-003 +0.011332
b2 -7.123 -0.62850 -7.87798
b3 +0.71808 +0.041501 +0.83819
b11 +8.0E-004 -2.080E-004 +4.8E-003
b22 -1.30 E-004 -1.80E-005 -4.3E-004
b33 0.10660 +9.894E-003 +0.1533
b12 -8.3985 -3.048E-007 -5.3E-006
b13 -0.2973 +0.041691 -0.44497
b23 -0.17368 -8.891E-003 -0.10202

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
8
 COMPARISON OF RSM & RA WITH ANN IN PREDICTING MECHANICAL PROPERTIES OF FRICTION STIR WELDED ALUMINUM PIPES

Design-Expert software
tensile strength
D e s ig n -E x p e rt®
t Colour
e n s i l epoint
s t rby
e nvalue
g th
S o ft w a r e
of
P r e d i c Predicted
t e d v svs.. actual
A c t u a l

Ctensile
o l o rstrength:
p o in t s b y va lu e o f
te n s ile s tre n g th : 220
2 2 0
2 0 5

1 3 4

200
2 0 0

Predicted
180
1 8 0

P r e d i c 160
t 1
e 6d 0

140
1 4 0

120
1 2 0

1 2 0 1 4 0 1 6 0 1 8 0 2 0 0 2 2 0
120 140 160 180 200 220
A
Actual
c t u a l

Fig. 15 : Relation between experimental tensile strength and predicted tensile strength

Design-Expert software
elongation
D e s ig n -E x p e rt® S o ft w a r e
e l o n point
Colour g a t i by
o n value of
P r e d i c Predicted
t e d vs.
v sactual
. A c t u a l

elongation
C o lo r p o in ts b y va lu e o f
e lo n g a t io n : 88
7 .1

3
77

66
Predicted

55
P r e d ic t e d
44

33

22
2
2 33 4
4
5
5
6
6
7
7
8
8
A Actual
c t u a l

Fig. 16 : Relation between experimental elongation per cent and predicted elongation per cent

Design-Expert software
hardness
D e s ig n -E x p e rt® S o ft w a r e P r e d i c t e d
h a rd n e s s
Colour point by value of
Predicted vs.v actual
s . A c t u a l

C o lo r p o in ts b y va
hardness lu e o f
h a rd n e s s : 80
8 0
6 9

3 9

70
7 0

60
Predicted

6 0

P r e d i c t e 5d0 50

40
4 0

3 0
30
3 0 4 0 5 0 6 0 7 0 8 0
30 40 50 60 70 80
A
Actual
c t u a l

Fig. 17 : Relation between experimental hardness and predicted hardness

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
9
 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

Fig. 18 : Relation between standard errors of tensile strength, travel speed and material thickness of A16061 (At rotational speeds
485-1800 RPM)

Desirability

A: rotation speed 1

B: material thickness 1

C: travel speed 1

Tensile strength 0.579332

Elongation 0.561096

0.616638
Hardness

0.765008
Combined

0.000 0.250 0.500 0.750 1.000

Fig. 19 : Optimization of parameters of FSW on responses

Artificial neural network (ANN) :

An artificial neural network (ANN) is an information-processing paradigm that is inspired by the way
biological nervous systems, such as the brain, process information. The key element of this mode is the
version framework of the information processing system. It is composed of a big number of much-interconnected
processing elements (neurons) working in conformity to solve specific problems. Artificial neural network
(ANNs), like people, learns by example. An artificial neural network (ANN) is configured for a specific
application, such as pattern recognition or data classification, through a learning process. Learning in biological
systems involves adjustments to the synaptic connections that exist between the neurons (Kanakaraja and
Hem, 2013; Arcakhoglue et al., 2004; Zhang and Friedrich, 2003; Khourshid and Sabry, 2013 and Khourshid

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
10
 COMPARISON OF RSM & RA WITH ANN IN PREDICTING MECHANICAL PROPERTIES OF FRICTION STIR WELDED ALUMINUM PIPES

Fig. 20 : Propagation artificial neural network

Fig. 21 : Relation between exprimental tensile strength and predicted tensile strength

Fig. 22 : Relation between exprimental elongation per cent and predicted elongation per cent

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
11
 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

Fig. 23 : Relation between exprimental hardness and predicted hardness

Fig. 24 : Relation between tensile test measurement and tensile tests predicted (response surface methodology, regression analy-
sis, artificial neural network)

et al., 2011 and 2015). In this study, neural network is used with a single hidden layer improved with numerical
optimization techniques. The topology architecture of feed-forward three-layered back propagation neural network is
illustrated in Fig. 19 and 20.
The equation is calculated as :
On = F (Ik * Wkn)

On is the neuron’s output, n is the number of the neuron,

Ik is the inputs of the neuron, k is the number of inputs,
Wkn are the weights of the neurons.
F is the Fermi function 1/[1+Exp{-4*(x-0.5)}]
Has been used for training the network model for tensile strength, the percentage of elongation and hardness
prediction. 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 aluminum alloy within the trained range.

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
12
 COMPARISON OF RSM & RA WITH ANN IN PREDICTING MECHANICAL PROPERTIES OF FRICTION STIR WELDED ALUMINUM PIPES

Fig. 25 : Relation between elongation measurement and elongation predicted (Response surface methodology, regression analysis,
artificial neural network)

Fig. 26 : The relation between hardness measurement and hardness predicted (Response surface methodology, regression analysis
and artificial neural network)

The results acquired after exercise and testing on artificial neural networks are shown in the (Fig. 21-23).
The comparative between response surface methodology, regression analysis and artificial neural network
for ultimate tensile strength, the present elongation per cent and nugget hardness are presented in (Fig. 17-20).

Conclusion :
– The FSW efficiency increases with decrease the joint efficiency of FS welded (ratio of ultimate
tesnsile strength of welded joint to that of the base material was found 80, 79 and 76 per cent in 6061
in thickness 2, 3 and 4 mm.
– A regression analysis model and response surface methodology have been proved to be successful in

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
13
 IBRAHEEM SABRY, AHMED M. EL-KASSAS, A.M. KHOURSHID AND H.M. HINDAWY

term of agreement with experimental results ratio, respectively 90 per cent and 94.6 per cent.
– ANN model has been proved to be successful in terms of agreement with experimental results ratio 96.5%.

REFERENCES
Ambrogio, G., Fratini, L. and Micari, F. (2006). Incremental forming of friction stir welded tailored sheets, In : Proceedings of the
8th Biennial ASME Conference on Engineering Systems Design and Analysis, ESDA2006.
Arcakhoglu, E., Cavusoglu, A. and Risen, A. (2004). Thermodynamic analyses of refrigerant mixtures using artificial neural
networks. J. Appl. Energy, 78 : 219-230.
Davies, R.W.S., Diamond, P. S., Sklad, S., Wazny, L., Kaunitz, B., Fulbright, D., Waldron and McTernan, K. (2005).
Friction-stir-joined aluminum sheet materials for heavy vehicle cab structures, In: Annual Progress Report: High Strength
Weight Reduction Materials, 2005.
Grant, G.J., Davies, R.W., Stephens, E.V., Wazny, S., Kaunitz, L. and Waldron, D.J. (2006). The formability of Friction
Stir Welds in automotive stamping environments. SAE Transactions J. Materials & Manufact., 114 (5) :619-629.
Kanakaraja, D. and Hema, P. (2013). Comparative study on different pin geometries of tool profile in friction stir welding
using artificial neural networks. Internat. J. Mechanical Engg. & Technol., 4 (2): ISSN 0976 – 6340 (Print), ISSN 0976-6359
online.
Khourshid, A.M., Bousaif, T. and Sabry, I. (2011). Welding of cylindrical parts by using Friction Stir Technique. Monufia
University.
Khourshid, A. M. and Sabry, I. (2013). Friction stir welding study on aluminum pipe. Internat. J. Mechanical Engg. &
Robotics Res., 2013.
Khourshid, A.M., Ahmed, M. El-Kassas and Sabry, Ibraheem (2015). Integration between artificial neural network and
responses surfaces methodology for modeling of Friction Stir Welding, Internat. J. Adv. Engg. Res. & Sci., 2 (3): 67-73.
Kim, I. S., Son, K.J., Yang, Y.S. and Karaganda, P. K. D. V. (2003). Sensitivity analysis for process parameter parameters
in GMA welding process using factorial design method. Internat. J. Machine Tools & Manufact.,43 : 763-776.
Klingensmith, S., DuPont, J.N. and Marder, A.R. (2005). Microstructural characterization of a double-sided Friction Stir
Weld on a superaustenitic stainless steel, Welding J., 84 (5): 77–85.
Plaintively, R., Koshy Mathews, P. and Murugan, N. (2011). Development of mathematical models to predict the mechanical
properties of friction stir welded AA6351 aluminum alloy. J. Engg. Sci. & Technol. Rev., 4 (1) : 25-31.
Ramasamy, S., Gould, D. and Workman (2002). Design of experiments study to examine the effect of polarity on stud
welding. Welding J., 81 : 19- 26.
Su, J.Q., Nelson,T.W., Mishra,R. and Mahoney, M.(2003). Mi-crostructural investigation of friction stir welded 7050- T654
aluminium. Act Mater., 51 (3) : 713- 729, doi:10.1016/S1359-6454(02)00449-4.
Zeng, W. M., Wu, H. L. and Zhang, J. (2006). Effect of tool wear on mechanical properties and acoustic emission of friction
stir welded 6061 Al alloy. Acta. Metallurgica. Sinica., 19 (1): 9-19.
Zhang, Z. and Friedrich, K. (2003). Artificial neural networks applied to polymer composites: A review. J. Composit. Sci.&
Technol., 63: 2029-2044.
Zhou, C., Yang, X. and Luan, G. (2006). Effect of root flaws in the fatigue property offriction stirs welds in 2024-T3 aluminum
alloys. Mater Sci.Engg., 418 : 155–160.

MEMBERS OF RESEARCH FORUM

AUTHOR FOR CORRESPONDENCE : CO-OPTED AUTHORS :
I. Sabry, Ahmed M. El-Kassas, A.M. Khourshid and H.M. Hindawy
Faculty of Engineering, Tanta University, EGYPT Faculty of Engineering, Tanta University, EGYPT
Email: Ibraheem.sabry@yahoo.com Email: abokassas@yahoo.com; drkhourshid@yahoo.com;

Engg. & Tech. in India; 8(1&2); Apr.& Oct., 2017 | 1-14 HIND INSTITUTE OF SCIENCE AND TECHNOLOGY
14