IMPROVING PROCESS QUALITY IN FRICTION WELDING FOR BIMETAL LUGS
Keywords:
Friction Welding, Bimetal Lugs, Design of Experiment, Full FactorialAbstract
The purpose of this study is to investigate the effect of process parameter settings on quality of bimetal lugs produced by friction welding process. The study was conducted in a local electrical power components manufacturer. The company faced high reject rates of bimetal lugs. To avoid disturbance to the actual production line, the relevant historical process data were extracted and analysed. The data were mapped into full factorial experimental design matrix. The significance of operating parameters, namely, the rotational speed, friction pressure and friction time were investigated. The data analysis reveals the recommended optimum setting should be; rotational speed at high level (1450 Rpm), friction pressure at low level (39.2 Pa) and friction time at low level (4 s). The first order models are also proposed for prediction of the responses; tensile strength, upset and temperature.References
Vill, V.I., 1962. Friction Welding of Metals. American Welding Society.
Montgometry, D.C., 2005. Design and Analysis of Experiments (6th edition). United States of America. : John Wiley & Sons, inc.
Fryman, M.A., 2002. Quality and Process Improvement (1st edition), United States of America. Delmar Thomson Learning.
Muhammad Fadlee bin Abu Bakar, 2012. Characterization of Operating Conditions for Ball Bearings Through Design of Experiment. Universiti Teknologi Malaysia: B. Eng. Report.
Mohamad Faizal Bin Anuar, 2008. Process Optimization of Vacuum Forming Process by Using Design of Experiment. Universiti Teknologi Malaysia: B. Eng. Report.
Sekharan Gopal, 2003. Optimization on solder paste printing parameters. Universiti Teknologi Malaysia: B. Eng. Report.
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