Vibration Signature Based Monitoring on FSW Process and Verification by FEA
Akshay Todakar, Nakandhrakumar R S, M Ramakrishnan and V Meenakshisundaram
Published: February 28, 2022
Abstract
Experimental study conducted during joining butt weld in FSW process on Al 6061 alloy of size 50 mm width X 100 mm length X 8 mm thickness of two plates wherein the effect of the interaction between the plates, tool and the vibration that occurs during the process are investigated, are reported. In this study, joining sides of the workpiece samples are artificially induced with air gaps of drilled holes in 2mm, 3mm, 5 mm diameter holes and 3mm width X 4 mm depth of slots in random distances. The vibration behaviour of the tool and workpiece joining system are characterized by a frequencies arrived in modal analysis using Finite Element Analysis (FEA), each mode corresponds to tool and workpiece system. Variations in the amplitudes of vibration signals in the particular range of frequencies from 6.0 to 7.0 kHz are proportional to workpiece and significant changes in linear pattern indicate the defective and steady joining area of workpiece. So, this method is effective in monitoring of workpiece joining in FSW process. The Fast Fourier Transform (FFT) analysis of vibration signal shows the changes in individual frequencies and is used for identifying the frequency range of monitoring workpiece with gap and without gap conditions. The steady joining portions cause the vibration which corresponds to 4thregion frequencies of workpiece.