Fabrication of FSW Tool Pins Through Turning of H13 Tool Steel: A Comparative Analysis for Residual Stresses.

In the present research, measurement of residual stress induced during turning and threading operations for the fabrication of two types of pin profiled friction stir processing/welding (FSP/FSW) tools, i.e. cylindrical profiled pin tool and cylindrical threaded profiled pin tool, is being dealt with. Workpiece was chosen to be H13 tool steel with a diameter of 22 mm and 110 mm length. Turning and threading was done on CNC machine tools using CNMG 12404-THM uncoated tungsten carbide cutting tool. For residual stress measurement of the workpieces, an XRD-based Pulsetec μ -X360n portable residual stress analyzer setup was used. The experimental results show that the cylindrical pin profile tool had a compressive residual stress of σ (x) = 3 0 1 MPa and compressive residual shear stress of τ (x y) = 6 0 MPa, while the cylindrical threaded pin profile tool had a compressive residual stress of σ (x) = 4 5 7 MPa (51.8% more) and compressive residual shear stress of τ (x y) = 3 6 MPa (40% less). It has been concluded that due to threading operation on the cylindrical threaded pin profile, the value of residual stress is more in it, and since the stress is compressive in nature, it would have a better positive impact while doing FSP/FSW than that of the cylindrical profiled pin tool. [ABSTRACT FROM AUTHOR]