In Friction Stir Welding (FSW) processes the axial force provides a forging action that affects the part's microstructure and, hence, its mechanical properties. Controlling this force provides good, consistent welding quality. The aim of this paper is to provide a systematic method to design and implement axial force controllers for FSW processes. The axial force is modeled as a nonlinear function of the measured FSW process parameters (i.e., plunge depth, traverse rate, and rotation speed) and the equipment is modeled as a pure delay from the commanded to the measured process parameters. Based on these dynamic models, a nonlinear feedback controller for the axial force is designed using Polynomial Pole Placement. This controller is implemented in a Smith Predictor-Corrector structure to compensate for the inherent equipment delay and the controller parameters are tuned to achieve the best closed-loop response given the equipment limitations. Experimental implementations verify the controller is able to maintain a constant axial force, even when gaps are encountered during the welding process.
- Axial flow,
- Dynamic models,
- Dynamic programming,
- Electric welding,
- Force control,
- Friction,
- Friction welding,
- Gas welding,
- Heat affected zone,
- Lithography,
- Mechanical properties,
- Welding,
- (PL) properties,
- Axial forces,
- Closed loops,
- Controller parameters,
- Friction STIR welding,
- Friction Stir Welding (FSW),
- Non linear functions,
- Nonlinear feedback controllers,
- Polynomial pole placement,
- Process Parameters,
- Pure delay,
- Rotation speeds,
- Smith predictors,
- Systematic methods,
- Traverse rate,
- welding processes,
- Welding quality,
- Process control
Available at: http://works.bepress.com/k-krishnamurthy/30/