Performance of Plunge Depth Control Methods During Friction Stir Welding
Abstract
:1. Introduction
2. Experimental Setup
3. Results and Discussion
3.1. Conventional Position Control
3.2. Offset Position Control
3.3. Deflection Compensation Control
4. Conclusions
- (1)
- When using the conventional position control, the actual plunge depth was below 3.0 mm. The pin could not reach the upper surface of the steel sheet due to system deflection, and proper welds were not established.
- (2)
- In the offset position control experiments, the desired plunge depth was most accurately achieved by applying an addition offset of 0.35 mm, when the welding speed and tool rotation speeds were at 150 mm/min and 700 rpm, respectively. However, the plunge depth continuously increased by 42 μm during the tool traverse phase, and the corresponding fracture load in the tensile test decreased from 4.2 to 3.3 kN due to increased heat input during the welding.
- (3)
- When the deflection compensation control was applied, precise control of the plunge depth was accomplished with a 3.3-µm standard deviation of error during the tool traverse phase. A bias of 32 μm into the DP steel was observed due to the resolution of the load sensor. This bias did not vary with the process parameters and could be easily removed to improve the control accuracy.
- (4)
- Temperature changes in the base materials causes in-situ variation of the system deflection during the tool traverse phase. The deflection compensation control method can adequately compensate for this variation, which is not compensated for by the offset position control, force control, or torque control.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Al 5083-O | |||||||||||
Si | Fe | Cu | Mn | Mg | Cr | Zn | Ti | Al | |||
0.14 | 0.26 | 0.04 | 0.69 | 4.54 | 0.11 | 0.01 | 0.02 | Bal. | |||
DP 590 | |||||||||||
C | Si | Mn | P | S | Fe | ||||||
0.078 | 0.362 | 1.809 | 0.0172 | 0.0014 | Bal. |
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Yoon, J.; Kim, C.; Rhee, S. Performance of Plunge Depth Control Methods During Friction Stir Welding. Metals 2019, 9, 283. https://doi.org/10.3390/met9030283
Yoon J, Kim C, Rhee S. Performance of Plunge Depth Control Methods During Friction Stir Welding. Metals. 2019; 9(3):283. https://doi.org/10.3390/met9030283
Chicago/Turabian StyleYoon, Jinyoung, Cheolhee Kim, and Sehun Rhee. 2019. "Performance of Plunge Depth Control Methods During Friction Stir Welding" Metals 9, no. 3: 283. https://doi.org/10.3390/met9030283