Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding
Despite increasing need for friction stir spot welding (FSSW) for high-temperature softening materials, system deflection due to relatively high plunging force remains an obstacle. System deflection results in the vertical position error of a welding tool and insufficient plunge depth. In this study...
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| Format: | Article |
| Language: | English |
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MDPI AG
2018-12-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/8/12/1049 |
| _version_ | 1811333568107905024 |
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| author | Jinyoung Yoon Cheolhee Kim Sehun Rhee |
| author_facet | Jinyoung Yoon Cheolhee Kim Sehun Rhee |
| author_sort | Jinyoung Yoon |
| collection | DOAJ |
| description | Despite increasing need for friction stir spot welding (FSSW) for high-temperature softening materials, system deflection due to relatively high plunging force remains an obstacle. System deflection results in the vertical position error of a welding tool and insufficient plunge depth. In this study, we used adaptive control to maintain plunge depth, the plunging force was coaxially measured, and the position error was estimated using a force⁻deflection model. A linear relationship was confirmed between the force and deflection; this relationship is dependent on the stiffness of the welding system while independent of process parameters and base materials. The proposed model was evaluated during the FSSW of an Al 6061-T6 alloy sheet and a dissimilar metal combination of Al 6061-T6 alloy/dual phase (DP) 590 steel. Under varying process parameters, the adaptive control maintained a plunge depth with an error of less than 50 μm. Conventional position control has a maximum error of nearly 300 μm. |
| first_indexed | 2024-04-13T16:54:54Z |
| format | Article |
| id | doaj.art-41a06dc8effb4b9db6c41a75c1df93f5 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-04-13T16:54:54Z |
| publishDate | 2018-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-41a06dc8effb4b9db6c41a75c1df93f52022-12-22T02:38:50ZengMDPI AGMetals2075-47012018-12-01812104910.3390/met8121049met8121049Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot WeldingJinyoung Yoon0Cheolhee Kim1Sehun Rhee2Joining Research Group, Korea Institute of Industrial Technology, Incheon 21999, KoreaJoining Research Group, Korea Institute of Industrial Technology, Incheon 21999, KoreaSchool of Mechanical Engineering, Hanyang University, Seoul 04763, KoreaDespite increasing need for friction stir spot welding (FSSW) for high-temperature softening materials, system deflection due to relatively high plunging force remains an obstacle. System deflection results in the vertical position error of a welding tool and insufficient plunge depth. In this study, we used adaptive control to maintain plunge depth, the plunging force was coaxially measured, and the position error was estimated using a force⁻deflection model. A linear relationship was confirmed between the force and deflection; this relationship is dependent on the stiffness of the welding system while independent of process parameters and base materials. The proposed model was evaluated during the FSSW of an Al 6061-T6 alloy sheet and a dissimilar metal combination of Al 6061-T6 alloy/dual phase (DP) 590 steel. Under varying process parameters, the adaptive control maintained a plunge depth with an error of less than 50 μm. Conventional position control has a maximum error of nearly 300 μm.https://www.mdpi.com/2075-4701/8/12/1049friction stir spot weldingplunge depthadaptive controlforce–deflection modelhigh-temperature softening materialsdissimilar metal welding |
| spellingShingle | Jinyoung Yoon Cheolhee Kim Sehun Rhee Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding Metals friction stir spot welding plunge depth adaptive control force–deflection model high-temperature softening materials dissimilar metal welding |
| title | Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding |
| title_full | Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding |
| title_fullStr | Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding |
| title_full_unstemmed | Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding |
| title_short | Compensation of Vertical Position Error Using a Force–Deflection Model in Friction Stir Spot Welding |
| title_sort | compensation of vertical position error using a force deflection model in friction stir spot welding |
| topic | friction stir spot welding plunge depth adaptive control force–deflection model high-temperature softening materials dissimilar metal welding |
| url | https://www.mdpi.com/2075-4701/8/12/1049 |
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