International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 6, November - December (2013) © IAEME 275 PREDICTION AND OPTIMIZATION OF PROCESS PARAMETERS FOR COPPER ALLOY TO CONTROL THE FLASH USING NON-TRADITIONAL ALGORITHM P. SHIVA SHANKAR Department of Mechanical Engineering, University College of Engineering and Technology, Mahatma Gandhi University, Nalgonda, Andhra Pradesh – 508001 ABSTRACT Friction welding is a solid state bonding technique which utilizes the heat generated by the faying surfaces. Friction welding is widely used for joining of similar and non- similar materials. Friction welding process is generally a multi input and multi output process, so we require the parameters to optimized for the sound weld. In present study the input variables are Friction pressure(FT), Friction time (FT), Upset time (UT) and Upset pressure (UP) similarly the output variables are considered to be Flash width (FW), Flash height (FH) and Flash thickness (FT). Empirical relation is formulated using by design Expert. Integration of these techniques in order to minimize the metal losses without sacrificing the Tensile Strength of the joints. INTRODUCTION Friction welding is a solid state welding process where the frictional heat is generated between the two faying surfaces. The temperature is raised up to higher interface enough to cause the two surfaces to be forged together under high forge pressure. In this friction welding we have two types of principles i.e, continuous drive friction welding for the circular geometry and linear friction welding for the other geometry like square, rectangular and etc. in continuous drive friction welding one of the work piece is fixed in rotating spindle which is driven by the motor, while the other is restricted form the rotation. the work piece in the spindle is rotated in a predetermined constant speed of 1500 rpm and the other is brought together with in 3 rd stage for the predetermined time or until a preset amount of axial shortening takes place and then the Forge pressure is applied. Lastely the rotation is stopped abruptly by the help of the braking force. INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND TECHNOLOGY (IJMET) ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online) Volume 4, Issue 6, November - December (2013), pp. 275-284 © IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com IJMET © I A E M E