Investigation of The Effect of Reduced Shank Thickness of Friction Welded Yoke Shaft on Strength

Abstract

Usage of friction welding method on the joints provides many advantages such as cost reduction, weight reduction and higher quality. The yoke shaft produced by rotary friction welding (RFW) involves a yoked part and a hollow round bar which are welded to each other. And so, no additional drilling method used in the way of removing material from the centre of the yoke shaft, is required to reduce the weight. The weight is inherently reduced thanks to hollow round bar used in RFW method. It is possible to use a friction welded yoke shaft in a wide range of wall thickness by removing material from the shank diameter for different applications. At this point, the key factor is strength of the friction welded yoke shaft with reduced wall thickness on the shank diameter. The aim of this study is investigation the effect of the reduced wall thickness of a yoke shaft produced by RFW on the strength. For this purpose, yoke shafts were manufactured by using RFW and consecutive processes such as turning and millings to reduce the wall thickness. The specimens in different wall thickness were tested to determine the strength. Additionally finite element analyses (FEAs) were implemented for each variation of the specimens and compared with the test results. As a result, it was determined that yoke shafts with reduced wall thicknesses, which were produced by RFW and then consecutively machining operations to obtain a specific wall thickness, can be used in drive shaft manufacturing securely.

Keywords

• Rotary friction welding
• Yoke shaft
• Wall thickness
• FEA

Sürtünme Kaynaklı Çatallı Milin Boğaz Cidar Kalınlığındaki Azaltmanın Dayanım Üzerindeki Etkisinin İncelenmesi

Abstract

Sürtünme kaynağı yönteminin birleştirmelerde kullanılması, maliyet düşürme, ağırlık azaltma ve daha yüksek kalite gibi birçok avantaj sağlar. Dönel sürtünme kaynağı (RFW) ile üretilen çatallı mil birbirine kaynaklanmış çatallı bir parça ve içi boş yuvarlak çubuk içerir. Ve bu nedenle, ağırlığı azaltmak için çatallı milin merkezinden malzeme azaltmak için kullanılan ek bir delme yöntemi gerekmez. RFW yönteminde kullanılan içi boş yuvarlak çubuk sayesinde ağırlık kendiliğinden azaltılmıştır. Farklı uygulamalar için boğaz çapından malzeme kaldırılarak çok çeşitli cidar kalınlıklarında sürtünme kaynaklı çatallı mil kullanmak mümkündür. Bu noktada kilit faktör, boğaz çapında azaltılmış cidar kalınlığına sahip sürtünme kaynaklı çatallı milin dayanımıdır. Bu çalışmanın amacı, RFW ile üretilen çatallı milin azaltılmış cidar kalınlığının parçanın dayanımı üzerindeki etkisinin araştırılmasıdır. Bu amaçla, RFW ve cidar kalınlığını azaltmak için tornalama ve frezeleme gibi ardışık işlemler kullanılarak çatallı miller üretilmiştir. Dayanımı belirlemek için farklı cidar kalınlıklarındaki numuneler test edilmiştir. Ek olarak, numunelerin her varyasyonu için sonlu eleman analizleri (FEA) uygulanmış ve test sonuçlarıyla karşılaştırılmıştır. Sonuç olarak RFW ve ardından belirli bir cidar kalınlığı elde etmek için ardışık talaşlı imalat işlemleri ile üretilen azaltılmış cidar kalınlığına sahip çatallı millerin kardan mili imalatında güvenle kullanılabileceği belirlenmiştir.

Keywords

• Dönel sürtünme kaynağı
• Çatallı mil
• Cidar kalınlığı
• FEA

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