In this thesis, friction stir channeling (FSC) and its process parameters influence on geometry, surface quality and productivity are explored. The probe of the friction stir processing (FSP) tool used to perform these tests was a modified submerged bobbin tool made of MP 159 Co-Ni alloy. The body was made from H13 tool steel. To find the optimal channel conditions for a targeted range of process parameters, multiple 6061 aluminum samples were prepared with a U shape guide to test the effects of different spindle speeds and feed rates. Using a gantry-type computer numerical control (CNC) friction stir welding (FSW) machine, the aluminum coupons were subjected to calibration experiments, force control tests, and an increased production rate to test these effects. It was found through experimentation that the programmed feed rates, spindle speeds and forces produced by the machine had an impact on the channel geometry. It was determined from the force-controlled setup that 8.46 mm/s at 750 RPM was the best combination of results for the four conditions tested on a CNC friction stir processing-machine. It was then tested at 10.58 mm/s at 800 RPM, which had comparable results with the best combination of input parameters from the force-controlled runs which demonstrates the utility of the process in high production settings. Finally, a proof-of-concept experiment was performed on a robotic arm outfitted with a FSW holder, showing acceptable results. This is a validation of its future implementation in the manufacturing of large parts for lightweight, aerospace, and automotive applications.
| Identifer | oai:union.ndltd.org:unt.edu/info:ark/67531/metadc1944372 |
| Date | 05 1900 |
| Creators | Koonce, James G |
| Contributors | Siller, Hector, Manzo, Maurizio (Aerospace and mechanical engineer), Mirshams, Reza, Mishra, Rajiv, Burford, Dwight |
| Publisher | University of North Texas |
| Source Sets | University of North Texas |
| Language | English |
| Detected Language | English |
| Type | Thesis or Dissertation |
| Format | Text |
| Rights | Public, Koonce, James G, Copyright, Copyright is held by the author, unless otherwise noted. All rights Reserved. |
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