DEPARTMENT OF MECHANICAL ENGINEERING

GOKARAJU RANGARAJU INSTITUTE OF ENGG & TECH (Autonomous) JNTUH, Hyderabad.

CERTIFICATE

This is to certify the Project entitled ANALYSIS AND FABRICTION OF A BUTT JOINT USING FRICTION STIR WELDING Submitted by Mr.ASGAR ULLAH KHAN bearing the Roll .No. 11241D5212 towards partial fulfillment of the requirements for the award of degree of Master of Engineering in Mechanical Engineering with specialization in Design for Manufacturing , from the Department of Mechanical engineering, Gojaraju Rangaraju Institute of Engg & Tech. (A), JNTUH, is a bonafide work carried out by him during the academic year 2011-2013. The content of this report have not been submitted to any other University or Institute for the award of degree.

Project Guide Dr. K.G.K MURTY Vice Principal

Head of Department

DECLARATION
I, Mr. ASGAR ULLAH KHAN hereby declare that the project work entitled ANALYSIS AND FABRICTION OF BUTT JOINT USING FRICTION STIR WELDING is an authenticated work carried out by me for the partial fulfillment of the award of degree of MASTER OF TECHNOLOGY in MECHANICAL ENGINEERING with specialization in Design for manufacturing, Rokaraju Rangaraju Institute of Engineering, and technology Autonomos under JNTUH. The contents of this thesis, in full or parts have not been submitted to any other institute or university for the award of any degree.

ASGAR ULLAH KHAN Roll No:11241D5212

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ACKNOWLEDGEMENT I write this acknowledgement with great honor, pride and pleasure to pay my respects to all who enabled me either directly or indirectly in reaching this stage. I am indebted forever to my guide Dr. K.G.K MURTY, Vice Principal Department of Mechanical Engineering, Gokaraju Rangaraju Institute Of Engg & Tech (A), for his suggestions, guidance and inspiration in carrying out this project. I express my profound thanks to Dr. S. Uday Bhaskar, Professor and Head of Mechanical engineering Department. AHCET for providing me with all the facilities to carry out this project work. I take this opportunity to express my sincere thanks to all the staff members of Department Of Mechanical Engineering, Gokaraju Rangaraju Institute Of Engg & Tech (Autonomous), JNTUH who contributed directly or indirectly to make this project success. I would like to thank my parents and family members for their love, patience and moral and financial support throughout the course. Finally I express my sincere thanks to all my classmates who contributed directly or indirectly to make this project success.

ASGAR ULLAH KHAN

ABSTRACT
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Aluminum alloy 6061 has gathered wide acceptance in the fabrication of light weight structures required a high strength to weight ratio. Compared to fusion welding processes that are routinely used for joining structural aluminum alloys, friction stir welding process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses non-consumable tool to generate frictional heat in the butting surfaces. The welding parameters tool pin profile plays a major role in deciding welding quality. In this project an attempt is made to understand the effect of welding speed and tool pin profile on FSP zone formation in Aluminum alloy 6061.Five different tool pin profiles are used to analys the welding joints. Those profiles are 1.Straight cylindrical, 2.Tapered cylindrical, 3.Threaded cylindrical, 4.Triangular, 5.Squre. In this project we are also doing coupled field analysis for both cutting tools and welding plates. We are also doing experimental work by using milling machine. In that we are preparing fixture, cutting tools and plates. Main parameters taken for this project are Cut feed, spindle RPM. Machine used for the experimental work are FN2 semi automatic machine. For modeling we are using Pro/Engineer soft ware, for analysis ANSYS

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