Design and Development of Load Member for Measuring Force and Torque in Friction Stir Welding Process

In today's manufacturing field, it's important to monitor and control the data related to operations involved in manufacturing industry. Especially for the processes like Friction Stir Welding/Processing, (FSW/FSP) which is a modern metal fusion technology invented in 1991. In this welding process, a non-consumable tool is used which rotates along the transverse direction and heat is produced due to friction between the tool's surface and the material. Researchers need to figure out how to optimize the forces and torque involved in this process to make the welding better. To do this, there is a need of a system that measures forces and torque involved in FSW. The latest FSW machines have built-in measurement systems for this, but for the older ones and milling machines used as FSW machine don't have any kind of measurement system. Strain gauge based measurement system which is cheap and reliable is generally used, these gauges are attached to a load member having a ring like structure which sense the force. In this Study design and development of the load member were discussed and an octagonal ring is found to be the best option for the load member. It responds well in measuring force and torque than other similar shapes. COMSOL multiphysics were used to model and simulate load members.