The development of a CNC-based technology FSW machine to accurately produce friction stir weld samples that can be analyzed for research purposes is implemented and discussed. A process diagnosis and control scheme to improve the process monitoring and weld evaluation capabilities of an FSW machine are proposed and implemented. Basic CNC-based hardware implementation such as optical encoders and inverters for process control are explained and verified. The control scheme and framework of interfaces to the digital I/O cards for PC user interface are explained. An advanced monitoring system which senses process performance parameters such as tool temperature, 3-axis tool forces, torque and spindle speed are explained. Mechanical designs and manufacturing techniques such as tool, clamp and backing plate designs are explained and verified. The process parameters for quality optimization are investigated and optimized by making use of Correlation and Regression Analysis. The statistical data and analytical relationships between welding parameters (independent) and each of the performance parameters (dependent) are obtained and used to simulate the machining process. The weld research samples are tested for strength and integrity making use of various scientific testing techniques. The reliability of the samples are also evaluated and compared to that of other institutions. Process variables and the optimum operating range of the Friction Stir Welding machine is determined and a framework for further research into weld quality optimization is set.
| Identifer | oai:union.ndltd.org:netd.ac.za/oai:union.ndltd.org:nmmu/vital:10809 |
| Date | January 2002 |
| Creators | Blignault, Calvin |
| Publisher | Port Elizabeth Technikon, Faculty of Engineering |
| Source Sets | South African National ETD Portal |
| Language | English |
| Detected Language | English |
| Type | Thesis, Masters, MTech (Mechanical Engineering) |
| Format | xxiii, 230 leaves, pdf |
| Rights | Nelson Mandela Metropolitan University |
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