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Article
Design and Implementation of a Nonlinear Axial Force Controller for Friction Stir Welding Processes
Proceedings of the American Control Conference (2007, New York, NY)
  • Zhao Xin
  • Prabhanjana Kalya
  • Robert G. Landers, Missouri University of Science and Technology
  • K. Krishnamurthy, Missouri University of Science and Technology
Abstract

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.

Meeting Name
2007 American Control Conference, ACC (2007: Jul. 9-13, New York, NY)
Department(s)
Mechanical and Aerospace Engineering
Keywords and Phrases
  • 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
International Standard Book Number (ISBN)
978-1424409884
Document Type
Article - Conference proceedings
Document Version
Citation
File Type
text
Language(s)
English
Rights
© 2007 Institute of Electrical and Electronics Engineers (IEEE), All rights reserved.
Publication Date
7-1-2007
Publication Date
01 Jul 2007
Citation Information
Zhao Xin, Prabhanjana Kalya, Robert G. Landers and K. Krishnamurthy. "Design and Implementation of a Nonlinear Axial Force Controller for Friction Stir Welding Processes" Proceedings of the American Control Conference (2007, New York, NY) (2007) p. 5553 - 5558 ISSN: 0743-1619
Available at: http://works.bepress.com/k-krishnamurthy/30/