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The considered process parameters are welding speed, tool rotation speed, shoulder diameter and plunging depth.
Samples were prepared and welded by varying input parameters such as tool rotation and weld speed.
For most of the experiments, the tool rotation γ (Eq. (4)) was between −1 and −2 mrad.
The surface roughness of wafers ground with increased pellet tool rotation speed became better and Ra=0.05 μm was achieved.
Higher tool rotation rate was found to causes a more uniform dispersion of reinforcing particles and thus, decreases particles clustering.
Among the parameters, tool rotation speed has a significant function in flushing away the debris to ensure stable discharge.
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To this end, this paper proposes the application of novel tool electrodes comprising geometric features specifically designed to promote tool rotation-induced debris egress.
The tool rotations around the x-, y-, and z-axes are denoted α, β, and γ, respectively.
The positive directions of tool rotations α, β, and γ are shown together with the coordinate system definition.
Experiments were carried out under different values of tool rotations and travel speeds under presence and absence of nanosilica addition.
Indeed by increasing the rotational speed to traverse speed ratio (w/v), the tool pin rotation rate in a certain distance increases, leading to a rise in strain of material under processing.
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