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A multi-objective optimization using response surface model coupled with particle swarm algorithm on FSW process
Parviz Kahhal1,2, Mohsen Ghasemi3, Mohammad Kashfi4
1School of Mechanical Engineering, Pusan National University, 2 Busandaehak-ro 63beon-gil, Geomjeong-gu, Busan, 46241, South Korea. parvizkahhal@abru.ac.ir.
This study optimizes friction-stir welding for AH12 1050 aluminum alloy using response surface methodology and particle swarm optimization. The findings enhance mechanical properties like strength and hardness, offering a cost-effective, accurate modeling approach.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Computational Mechanics
Background:
- Friction-stir welding (FSW) is a critical solid-state joining process for aluminum alloys.
- Optimizing FSW parameters is essential for achieving desired mechanical properties in the heat-affected zone (HAZ).
- Existing methods often lack comprehensive multi-objective optimization for complex property sets.
Purpose of the Study:
- To perform multi-objective optimization of mechanical properties in friction-stir welding of AH12 1050 aluminum alloy.
- To investigate the influence of process parameters and pin geometry on yield strength, fracture strain, impact toughness, and hardness.
- To validate the optimization model against experimental results.
Main Methods:
- Utilized a combination of Response Surface Methodology (RSM) and Multi-Objective Particle Swarm Optimization (MOPSO) algorithm.
- Considered key process parameters: tool pin diameter, shoulder diameter, rotational speed, feed speed, and tool tilt angle.
- Evaluated threaded and simple conical pin geometries for their effect on mechanical properties.
Main Results:
- Optimization model outputs showed strong agreement with experimental results.
- Lower rotational speed and higher feed speed were found to improve material strength and hardness.
- Threaded cylindrical pins demonstrated improved material flow and enhanced mechanical properties compared to conical pins.
- Microstructural analysis confirmed a fine-grained structure with minimal defects.
Conclusions:
- The integrated RSM and MOPSO approach provides accurate modeling and optimization for FSW processes.
- Optimized parameters and pin design significantly enhance mechanical properties and microstructure of welded AH12 1050 aluminum alloy.
- This methodology offers a cost-effective solution for optimizing advanced manufacturing processes.
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