Skin friction coefficient on a yarn package surface in ring spinning

The skin friction coefficient on the surface of a rotating yarn package affects the power required to drive the package. This paper examines the relationship between the skin friction coefficient on the package surface and its diameter and rotating speed, based on the fundamentals of aerodynamics and the experimental results of power consumption. Skin friction coefficients on the surfaces of an airplane, car top, and yarn package are discussed. The results indicate that the skin friction coefficient on the package surface without hairiness depends on the package diameter and spindle speed only. The skin friction coefficient on the yarn package surface is about three times that on the top surface of a car, and is about twenty times that on an airplane surface. The power consumed to overcome skin friction drag is more than that consumed to drive the spindle if the spindle speed is very slow. However, the situation reverses when the spindle speed is fast.

Friction changes during compression tests using tool rotation technique

A compression test with rotating dies was employed to estimate the friction factor between aluminum samples and steel tooling during large plastic deformations. A cylindrical workpiece was compressed under dry and cold conditions. The magnitudes of torque and normal force were measured and
the average friction factor was calculated using the Coulomb friction law. It was found that under certain conditions the friction increased with increasing angular velocity of the die. This finding led to the conclusion that the choice of die rotation speed is important in interpreting the results from the twist compression test.

Application of bending under tension test to determine the effect of tool radius and the contact pressure on the coefficient of friction in sheet metal forming

To quantify the frictional behaviour in sheet forming operations, several laboratory experiments which simulate the real forming conditions are performed. The Bending Under Tension Test is one such experiment which is often used to represent the frictional flow of sheet material around a die or a punch radius. Different mathematical representations are used to determine the coefficient of friction in the Bending Under Tension Test. In general the change in the strip thickness in passing over the die radius is neglected and the radius of curvature to thickness ratio is assumed to be constant in these equations. However, the effect of roller radius, sheet thickness and the surface pressure are also omitted in some of these equations. This work quantitatively determined the effect of roller radius and the tooling pressure on the coefficient of friction. The Bending Under Tension Test was performed using rollers with different radii and also lubricants with different properties. The tool radii were found to have a direct influence in the contact pressure. The effect of roller radius on friction was considerable and it was observed that there is a clear relationship between the contact pressure and the coefficient of friction.

Experimental analysis of friction in forming automotive coated steels

The thesis addressed and answered a number of key issues in the experimental analysis of friction in sheet forming operations. Conventional friction theories were linked with the properties of sheet coatings and the process geometries. Newly derived mathematical models extended the analysis of friction in sheet metal forming applications.

Correlation between shoulder flow zone quality and material flow quantity during friction stir welding of thick aluminum section using scroll shoulder tool

The so-called scroll shoulder tool is widely used particularly for thick section friction stir welding (FSW). However, the correlation between its shoulder flow zone weld quality and material flow quantity remains unclear. This information is important for tool design. In the present study, a scroll shoulder tool was used to FSW 20mm thick 6061 aluminum (Al) plates at a range of welding parameters. The pick-up material (PUM) by the scroll was quantified, and the effect of welding parameters and PUM on the shoulder flow zone formation and weld quality was studied. It was found that there is a positive linear relationship between the PUM and weld quality. In order to obtain a defect-free FSW weld produced by the scroll shoulder tool, scroll groove needs to be fully filled by PUM.

Material flow forming the shoulder flow zone using scroll shoulder tool during friction stir welding of thick section aluminum alloys

Scroll shoulder tools are widely used and they do not need to be tilted during friction stir welding (FSW). However, the detailed material flow, which is important for proper scroll shoulder tool design and subsequently for forming the defect-free shoulder flow zone, has not been fully explained. In the present study, features of material flow in shoulder flow zone, during FSW of thick 6061 aluminium (Al) plates using a scroll shoulder tool were investigated. It was observed that there is a simple layer-to-layer banded structure which appears in the bottom portion of shoulder flow zone, but disappears in the top portion of this weld zone. When the scroll shoulder tool is plunged into the workpiece to a determined depth, the workpiece material is extruded by the tool pin, and pushed up into the scroll groove beneath the shoulder forming the pick-up material. During the forward movement of the tool, the central portion of pick-up material was driven downward by the root portion of pin and then it detaches from the tip portion of pin in a layer-to-layer manner to form the weld.

Effect of tool speeds during friction stir lap welding on mode of fracture and fracture strength of Al 6060-T5 joints

Friction stir lap welding (FSLW) of an age hardened Al alloy and evaluations of how FS speeds affected hooking and how hooking and softening due to FS affected fracture strength of the lap welds have been conducted. It was found that increasing rotation speed and reducing welding speed (v) increased the stir zone size (AB-SZ) and also hook size (h), although a maximum value of h (hMax) reached. The features of hooks for the observed - AB-SZ-h relationships are presented and explained. It was found that when h increased to a value of ~ 0.9 mm (for the 3 mm alloy sheets), it started to invoke a significant effect on reducing fracture strength. Factors such as FS softening and insufficient joining, limited the fracture strength of the lap welds for small h values and these are presented and discussed.

Fracture strengths of Mg alloy AZ31B-H24 friction stir lap welds

The effects of selected friction stir lap welding parameters on fracture strength of Mg alloy AZ31B-H24 welds have been studied. Rotation speed has been found to affect significantly the flow related hook size formation. Furthermore, fracture strength decreased almost linearly with hook size. A small amount of softening was detected in fracture location that was outside the nugget zone and thus this softening may only adversely affect the fracture strength slightly. Finally, simulation results are presented to show the uneven stress distribution in a lap geometry which together with the relative brittleness of the stir material must be the cause to have significantly reduced the fracture strength.