A Hybrid Framework for Controlling the Zener-Hollomon Parameter in Friction Stir Processes (FSP) of Mg AZ31b
- Advisor: Ramsey Hamade
- Student: Ali Ammouri
Introduced in this work is an innovative hybrid framework for controlling the Zener-Hollomon parameter in friction stir processes by online manipulation of the process parameters and the temperature conditions. Process parameters such as the rotational speed of the pin, the plunging and traverse speeds, and the dwelling time along with a hybrid temperature conditioning system comprising a combination of intermittent cryogenic cooling, subzero air-cooling, closed loop chilled water circulation, and hot air preheating are actively controlled to achieve a prescribed Z parameter during a friction stir process. The system is guided by mathematical models obtained from the results of FEM simulations of the friction stir processes beside a blend of different types of sensors that monitor the whole process.
A 3D FEM model of the process is first used to study the sensitivity of each process parameter by running a selective test matrix and constructing a model that relates the parameters to desired output, Z in this case. The model is validated by comparing its state variable outputs to experimental results that will be run in house and compared to existing previous work in the literature.
The experiments will be run on a CNC milling machine customized to suite friction stir processes and equipped with a fusion of sensors including temperature probes, 3-axis force dynamometer, current transducers (to monitor drive and spindle motor), and an infrared imagery system. Optical microscopy and SEM observations will be used to compare the outputs of the experimental trials to the FEM simulations.
Preliminary published results of our FEM model showed close matching with existing experimental values in the literature. The use of current transducers on both the spindle and driver motors along with a sensor fusion system to monitor tool wear was also published in several referred journals and conferences.
A 3D FEM model of the process is first used to study the sensitivity of each process parameter by running a selective test matrix and constructing a model that relates the parameters to desired output, Z in this case. The model is validated by comparing its state variable outputs to experimental results that will be run in house and compared to existing previous work in the literature.
The experiments will be run on a CNC milling machine customized to suite friction stir processes and equipped with a fusion of sensors including temperature probes, 3-axis force dynamometer, current transducers (to monitor drive and spindle motor), and an infrared imagery system. Optical microscopy and SEM observations will be used to compare the outputs of the experimental trials to the FEM simulations.
Preliminary published results of our FEM model showed close matching with existing experimental values in the literature. The use of current transducers on both the spindle and driver motors along with a sensor fusion system to monitor tool wear was also published in several referred journals and conferences.