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Kuo CC, Gurumurthy N, Huang SH. Effects of Ambient Temperature on the Mechanical Properties of Frictionally Welded Components of Polycarbonate and Acrylonitrile Butadiene Styrene Dissimilar Polymer Rods. Polymers (Basel) 2023; 15:3637. [PMID: 37688263 PMCID: PMC10490424 DOI: 10.3390/polym15173637] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/24/2023] [Revised: 08/24/2023] [Accepted: 09/01/2023] [Indexed: 09/10/2023] Open
Abstract
Rotary friction welding (RFW) has no electric arc and the energy consumption during welding can be reduced as compared with conventional arc welding since it is a solid-phase welding process. The RFW is a sustainable manufacturing process because it provides low environmental pollution and energy consumption. However, few works focus on the reliability of dissimilar polymer rods fabricated via RFW. The reliability of the frictionally welded components is also related to the ambient temperatures. This work aims to investigate the effects of ambient temperature on the mechanical properties of frictionally welded components of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) dissimilar polymer rods. It was found that the heat-affected zone width increases with increasing rotational speeds due to peak welding temperature. The Shore A surface hardness of ABS/PC weld joint does not change with the increased rotational speeds. The Shore A surface hardness in the weld joint of RFW of the ABS/PC is about Shore A 70. The bending strength was increased by about 53% when the welded parts were placed at 60-70 °C compared with bending strength at room temperature. The remarkable finding is that the bending fracture position of the weldment occurs on the ABS side. It should be pointed out that the bending strength can be determined by the placed ambient temperature according to the proposed prediction equation. The impact energy was decreased by about 33% when the welded parts were placed at 65-70 °C compared with the impact energy at room temperature. The impact energy (y) can be determined by the placed ambient temperature according to the proposed prediction equation. The peak temperature in the weld interface can be predicted by the rotational speed based on the proposed equation.
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Affiliation(s)
- Chil-Chyuan Kuo
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
- Research Center for Intelligent Medical Devices, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
- Department of Mechanical Engineering, Chang Gung University, No. 259, Wenhua 1st Road, Guishan District, Taoyuan City 33302, Taiwan
- Center of Reliability Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
| | - Naruboyana Gurumurthy
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
- Department of Mechanical Engineering, Presidency University, Rajankunte, Near Yelhanka, Bangalore 700073, India
| | - Song-Hua Huang
- Li-Yin Technology Co., Ltd., No. 37, Lane 151, Section 1, Zhongxing Road, Wugu District, New Taipei City 24101, Taiwan
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Kuo CC, Gurumurthy N, Hunag SH. Fatigue Behavior of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Dissimilar Materials. Polymers (Basel) 2023; 15:3424. [PMID: 37631481 PMCID: PMC10457864 DOI: 10.3390/polym15163424] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/16/2023] [Revised: 08/09/2023] [Accepted: 08/15/2023] [Indexed: 08/27/2023] Open
Abstract
Understanding the fatigue behaviors of weld joints is significant in engineering practice. Rotary friction welding (RFW) can join the additively manufactured polymer components. Until now, no research has focused on the fatigue behavior of polymer components jointed via RFW. This study investigates the fatigue life of ABS/PC dissimilar components fabricated via RFW and proposes the fatigue mechanism based on the failure structure. This work uses five different cyclic loads and rotational speeds to investigate the fatigue life. The fatigue life of the RFW of ABS/PC dissimilar rods is better compared with the pure ABS and pure PC specimens due to weld and integrity microstructural changes resulting from the combination of ABS and PC materials. The number of cycles until the rupture of RFW of ABS/PC dissimilar components (y) can be determined by the cyclic load (x) according to the prediction equation of y = -838.25x2 - 2035.8x + 67,262. The fatigue life of the RFW of ABS/PC dissimilar components increase with the increased rotational speed. The number of cycles until rupture (y) can be determined by the different rotational speeds (x) according to the prediction equation of y = 315.21x2 + 2710.4x + 32,124.
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Affiliation(s)
- Chil-Chyuan Kuo
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
- Research Center for Intelligent Medical Devices, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
- Department of Mechanical Engineering, Chang Gung University, No. 259, Wenhua 1st Rd., Guishan Dist., Taoyuan City 33302, Taiwan
- Center for Reliability Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
| | - Naruboyana Gurumurthy
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, Taishan District, New Taipei City 24301, Taiwan
- Department of Mechanical Engineering, Presidency University, Rajankunte, Near Yelhanka, Bangalore 700073, India
| | - Song-Hua Hunag
- Li-Yin Technology Co., Ltd., No. 37, Lane 151, Section 1, Zhongxing Road, Wugu District, New Taipei City 24101, Taiwan
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Kuo CC, Gurumurthy N, Chen HW, Hunag SH. Experimentation and Numerical Modeling of Peak Temperature in the Weld Joint during Rotary Friction Welding of Dissimilar Plastic Rods. Polymers (Basel) 2023; 15:polym15092124. [PMID: 37177272 PMCID: PMC10181457 DOI: 10.3390/polym15092124] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/22/2023] [Revised: 04/23/2023] [Accepted: 04/26/2023] [Indexed: 05/15/2023] Open
Abstract
Rotary friction welding (RFW) could result in lower welding temperature, energy consumption, or environmental effects as compared with fusion welding processes. RFW is a green manufacturing technology with little environmental pollution in the field of joining methods. Thus, RFW is widely employed to manufacture green products. In general, the welding quality of welded parts, such as tensile strength, bending strength, and surface hardness is affected by the peak temperature in the weld joint during the RFW of dissimilar plastic rods. However, hitherto little is known about the domain knowledge of RFW of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) polymer rods. To prevent random efforts and energy consumption, a green method to predict the peak temperature in the weld joint of dissimilar RFW of ABS and PC rods was proposed. The main objective of this work is to investigate the peak temperature in the weld joint during the RFW using COMSOL multiphysics software for establishing an empirical technical database of RFW of dissimilar polymer rods under different rotational speeds. The main findings include that the peak temperature affecting the mechanical properties of RFW of PC and ABS can be determined by the simulation model proposed in this work. The average error of predicting the peak temperature using COMSOL software for five different rotational speeds is about 15 °C. The mesh element count of 875,688 is the optimal number of meshes for predicting peak temperature in the weld joint. The bending strength of the welded part (y) using peak welding temperature (x) can be predicted by the equation of y = -0.019 x2 + 5.081x - 200.75 with a correlation coefficient of 0.8857. The average shore A surface hardness, impact energy, and bending strength of the welded parts were found to be increased with increasing the rotational speed of RFW.
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Affiliation(s)
- Chil-Chyuan Kuo
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Research Center for Intelligent Medical Devices, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Department of Mechanical Engineering, Chang Gung University, No. 259, Wenhua 1st Road, Guishan District, Taoyuan City 33302, Taiwan
| | - Naruboyana Gurumurthy
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Department of Mechanical Engineering, Presidency University, Rajankunte, Near Yelhanka, Bangalore 700073, India
| | - Hong-Wei Chen
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
| | - Song-Hua Hunag
- Li-Yin Technology Co., Ltd., No. 37, Lane 151, Section 1, Zhongxing Road, Wugu District, New Taipei City 241, Taiwan
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Kuo CC, Gurumurthy N, Chen HW, Hunag SH. Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods. Materials (Basel) 2023; 16:ma16093295. [PMID: 37176175 PMCID: PMC10179590 DOI: 10.3390/ma16093295] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/31/2023] [Revised: 04/20/2023] [Accepted: 04/21/2023] [Indexed: 05/15/2023]
Abstract
Rotary friction welding (RFW) is a green manufacturing technology with environmental pollution in the field of joining methods. In practice, the welding quality of the friction-welded parts was affected by the peak temperature in the weld joint during the RFW of dissimilar plastic rods. In industry, polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) are two commonly used plastics in consumer products. In this study, the COMSOL multiphysics software was employed to estimate the peak temperature in the weld joint during the RFW of PC and ABS rods. After RFW, the mechanical performance and microstructural evolution of friction-welded parts were investigated experimentally. The average Shore A surface hardness, flexural strength, and impact energy are directly proportional to the rotation speed of the RFW. The quality of RFW is excellent, since the welding strength in the weld joint is better than that of the ABS base materials. The fracture occurs in the ABS rods since their brittleness is higher than that of the PC rods. The average percentage error of predicting the peak temperature using COMSOL software using a mesh element count of 875,688 for five different rotation speeds is about 16.6%. The differential scanning calorimetry curve for the friction-welded parts welded at a rotation speed of 1350 rpm shows an endothermic peak between 400 to 440 °C and an exothermic peak between 600 to 700 °C, showing that the friction-welded parts have better mechanical properties.
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Affiliation(s)
- Chil-Chyuan Kuo
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Research Center for Intelligent Medical Devices, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Department of Mechanical Engineering, Chang Gung University, No.259, Wenhua 1st Rd., Guishan Dist., Taoyuan City 333, Taiwan
| | - Naruboyana Gurumurthy
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Department of Mechanical Engineering, Presidency University, Rajankunte, Near Yelhanka, Bangalore 700073, India
| | - Hong-Wei Chen
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
| | - Song-Hua Hunag
- Li-Yin Technology Co., Ltd., No. 37, Lane 151, Section 1, Zhongxing Road, Wugu District, New Taipei City 241, Taiwan
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