Conference Papers
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Item Taguchi method of optimization of process variables for ultimate tensile strength of friction stir welded joint of Al-Ce-Si-Mg aluminium alloy plates(Elsevier Ltd, 2021) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.A novel method of welding known as friction stir welding or FSW has found wide applications in metal joining industries now a days. There are various process input variables which affect the output quality characteristic or response of the weld joint produced. Speed of tool rotation, tool feed and tool pin contour are important input process variables and ultimate tensile stress (UTS) of the FSW joint is the output response considered in this research. The Taguchi method of Design of Experiments type optimization was used to find the level and contribution of each of these input process variables on output quality characteristic of the FSW butt joint produced on plates of Al-Ce-Si-Mg aluminium alloy material. Taguchi L9 orthogonal array type design was utilized to bring down the number of experiments from 27 to 9 for a 3 factor, 3 levels each, analysis. The results of Taguchi analysis indicated that the speed of tool rotation at 1200 rpm, tool feed at 15 mm/min and triangular shape pin tool gave the peak output UTS. The ANOVA tests demonstrated that the contribution percentage of the tool pin contour at 41%, speed of tool rotation at 29%, and tool feed at 22%, showing that the tool pin contour has maximum bearing on the output quality characteristics, i.e., UTS of the FSW joint. The optimum UTS predicted by the Taguchi analysis was 88.29 MPa, whereas the confirmation experiments gave a result of 80.54 MPa, which was well inside the confidence interval predicted by the Taguchi design. © 2021 Elsevier Ltd. All rights reserved.Item Process parameter optimization for ultimate tensile strength of friction stir welded joint of Al-10Mg-8Ce-3.5Si aluminium alloy plates using Taguchi technique(Elsevier Ltd, 2022) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.The Friction stir welding (FSW) process has become a popular method of joining metals, due to its clean and efficient nature of producing welds. The input process parameters: the tool rotation speed, tool feed and tool pin shape are the deciding parameters for an optimum output quality characteristic, the Ultimate tensile stress (UTS) of the weld joint. Here in this research, the Taguchi full factorial design technique is discussed for maximizing the UTS of the weld joint formed in Al-10Mg-8Ce-3.5Si aluminium alloy plates. The ANOVA of means and Signal to Noise ratios for UTS was used to assess the influence of each of the input process parameters on output UTS. The main effect plots of the ANOVA results demonstrated that, the tool rotation speed at level 2 or 1000 rpm, the tool feed at level 3 or 20 mm/min and tool pin shape at level 1 or triangular cross section, gave the optimum results for output UTS. The ANOVA for UTS also showed the percentage contribution of input process parameters; the shape of tool pin as 60.06%, the tool feed as 15.42% and shape of tool pin as 2.41%. The UTS value predicted by the Taguchi analysis was at 108.47 MPa which was in good agreement with the experimentally obtained value of 106.84 MPa. A nonlinear regression equation was developed by correlating the input process parameters, which could be used to predict the optimum UTS results. © 2022 Elsevier Ltd. All rights reserved.