Spindle Torque Research Articles

Active compliance control of grinding process for stripping enameled copper wire

The hairpin motor is among the motors used in eco-friendly automobiles. Unlike the random-winding method, this method features a square cross-sectional enamel coil formed into several hundred hairpins inserted into the stator. This offers an increased space factor, which leads to enhanced motor power. With the growing use of hairpin motors, there is an increasing demand for automated equipment in their production. With an aim to improve the manufacturing quality of hairpin motors, many countries are conducting research and development. The process of enamel removal is one of the key steps in hairpin-forming equipment and can significantly affect the performance of the motor. A precise machining process technology is required to improve the enamel removal process, achieve higher enamel removal rates, and reduce wire loss rates. Grinding is a technique used for enamel removal. In this study, an adaptive control algorithm was applied to the grinding process to enhance the enamel removal machining performance. During the machining process, the vertical position of the spindle was controlled to maintain a consistent machining depth for tracking the target grinding force. An experimental setup, which included a system for measuring the spindle torque to calculate the grinding force in real time, was created. To validate the performance of the adaptive control technology, experiments were conducted using this setup. Furthermore, experiments were conducted to observe the changes in the grinding force ratio based on the conditions of the grinding wheel. The correlation between the grinding force ratio and tool condition was analyzed, and based on this, the feasibility of assessing tool condition and determining the timing for tool replacement through real-time monitoring of the grinding force ratio was confirmed.

A Novel Method on Recognizing Drum Load of Elastic Tooth Drum Pepper Harvester Based on CEEMDAN-KPCA-SVM

The operational complexities of the elastic tooth drum pepper harvester (ETDPH), characterized by variable drum loads that are challenging to recognize due to varying pepper densities, significantly impact pepper loss rates and mechanical damage. This study proposes a novel method integrating complete ensemble empirical mode decomposition with adaptive noise (CEEMDAN), kernel principal component analysis (KPCA), and a support vector machine (SVM) to enhance drum load recognition. The method consists of three principal steps: the initial experiments with ETDPHs to identify the critical factors affecting drum load and to formulate classification criteria; the development of a CEEMDAN-KPCA-SVM model for ETDPH drum load recognition, where drum spindle torque signals are processed by CEEMDAN for decomposition and reconstruction, followed by feature extraction and dimensionality reduction via KPCA to refine the model’s accuracy and training efficiency; and evaluation of the model’s performance on real datasets, highlighting the improvements brought by CEEMDAN and KPCA, as well as comparative analysis with other machine learning models. The results describe four load conditions—no load (mass of pepper intake (MOPI) = 0 kg/s), low load (0 < MOPI ≤ 0.658 kg/s), normal load (0.658 < MOPI ≤ 1.725 kg/s), and high load (MOPI > 1.725 kg/s)—with the CEEMDAN-KPCA-SVM model achieving 100% accuracy on both training and test sets, outperforming the standalone SVM by 6% and 12.5%, respectively. Additionally, it reduced the training time to 2.88 s, a 10.9% decrease, and reduced the prediction time to 0.0001 s, a 63.6% decrease. Comparative evaluations confirmed the superiority of the CEEMDAN-KPCA-SVM model over random forest (RF) and gradient boosting machine (GBM) in classification tasks. The synergistic application of CEEMDAN and KPCA significantly improved the accuracy and operational efficiency of the SVM model, providing valuable insights for load recognition and adaptive control of ETDPH drum parameters.

Enhancing joint performance in friction stir welding through tailored double-butt-lap geometry

The study investigates the effectiveness of a novel joint configuration, the double-butt-lap (DBL), in friction stir welding (FSW) to join 6-mm-thick AA 6061-T6 plates. Four welds, including a simple square butt (SSB) configuration and three DBL variations (with UB to LB ratios of 1:2, 1:1, and 2:1), were executed. Using consistent parameters, the investigation evaluates the force distribution, macrostructure, and mechanical properties of the joints. Results show varied force profiles; spindle torque and Z-force decrease notably in DBL configurations compared to SSB, while X-force decreases overall for all DBL variations. Macrostructural analysis indicates increased weld area and finer microstructures in DBL joints. A correlation between peak temperature, grain size, and hardness highlights larger grain sizes at higher temperatures, influencing joint hardness. The DBL configuration with a 2:1 ratio exhibits the highest joint efficiency (83.76%). Fractographic analysis indicates ductile failure in all samples. Bend testing reveals increased flexural strength and bend angles in two DBL-configured joints compared to SSB. The results indicate that using a 2:1 ratio for joining 6-mm AA6061-T6 plates through FSW is viable, providing valuable insights into enhancing mechanical properties by optimizing joint geometry.

Numerical simulation of material flow and defect formation during FSW to predict weld failure location

Predicting the failure location of welded specimens is of importance for various industrial applications. In friction stir welding, material flow and eventually defect have an effect on the failure location. In the current work, a three-dimensional coupled Eulerian Lagrangian (CEL) is developed to study the material flow and predict defects originating during friction stir welding of AA2024 having a thickness of 3 mm. To minimize defects and achieve good weld quality, a square-shaped pin is used. The developed model is validated with experimentally observed axial force and spindle torque. Numerically predicted defects have been validated with experimental fracture locations and strength to test the robustness of the model in quantifying defects. Peak temperature increased by 10.7% when rotational speed was increased from 600 to 1500 rpm. Also, the peak temperature rise of 6.1% is observed when the welding speed is increased from 60 to 150 mm/min. Higher rotational and welding speed led to lower defects. At 1500 rpm and 150 mm/min process conditions, the highest weld strength of 447 MPa is obtained. Material flow analysis is carried out for varying process parameters; an intermixing of material flow with a zig-zag pattern is observed for 1500 rpm, indicating better material flow as compared with 600 rpm.

Effects of alignment discrepancies on the weld quality in friction stir welding

Friction stir welding is a modern welding technology with which the joining partners are welded in the solid state. The technology is often employed in the aerospace industry due to the excellent mechanical properties of the weld. Process disturbances can cause irregularities in the weld quality. It is still a challenge to avoid part fit-up deviations as a result of part misalignments and tolerances. Several publications have investigated the effect of alignment discrepancies on the weld quality, for example, by introducing a gap between parts, a tool offset, or linearly misaligned sheets. Depending on the application, the effects of simultaneously occurring alignment discrepancies on the weld quality could be critical. In this work, three alignment discrepancies were investigated (gap, linearly misaligned sheets, tool offset). The weld quality was determined using tensile tests. Process data such as the process forces and the spindle torque were also measured during the welding experiments. The results showed that each of the alignment discrepancies had a negative impact on the weld quality. The simultaneous occurrence resulted in an even lower weld quality. Some alignment discrepancies can probably be detected in the future using process data (e.g., the lateral force).

Effect of tool traverse speed on high strength structural AA6092/17.5 SiCp-T6 AMC friction stir welding

This study systematically explores the impact of Tool Traverse Speed (TTS) in Friction Stir Welding of aerospace-grade AA6092/17.5 SiCp-T6 Aluminium Matrix Composites. The TTS varied in the range of 0.5 to 3.5 mm/s with Tool Rotation Speed and Tool Tilt Angle being constant. Results indicate that the maximum peak temperature is achieved at 0.5 mm/s, gradually decreasing with increasing TTS up to 3.5 mm/s. Significant fluctuations in spindle torque and Z-force are observed, with values doubling between 0.5 mm/s and 3.5 mm/s TTS. Notably, both extremes of TTS exhibit significant tool wear. Examining the microstructure shows that as the TTS increases up to 2 mm/s, there is a reduction in the particle size while the particle density within the matrix rises. Hardness reaches its maximum at 2.75 mm/s, aligning with the best joint performance and impact resistance. Mechanical property evaluations show joint efficiency increasing from 62% at 0.5 mm/s to 90% at 2 mm/s, then decreasing to 60% at 3.5 mm/s TTS. Impact strength follows a similar trend, peaking at 20.7 J at 2.75 mm/s TTS. This study identifies the optimal TTS range of 1.25 mm/s to 2.75 mm/s, striking a balance between improved mechanical performance and microstructural refinement.

Effect of Workpiece/Tool Heat Transfer and Friction Coefficients on Accuracy of Simulated Temperatures and Torques in a Friction Stir Welding Plunge.

Friction stir process models are typically validated by tuning heat transfer and friction coefficients until measured temperatures in either the tool or workpiece, but rarely in both, match simulated results. A three-dimensional finite element model for a tool plunge in an AA 6061-T6 is validated for temperature predictions in both the tool and workpiece using a friction coefficient that varies with time. Peak workpiece temperatures were within 1.5% of experimental temperatures and tool temperatures were off by 80 °C. The sensitivity of the predicted temperatures with respect to the workpiece/tool heat transfer coefficient was shown to be high for the tool and low for the workpiece, while the spindle torque was slightly underpredicted in the best case. These results show that workpiece/tool interface properties must be tuned by considering predictions on both sides of the heat generation interface in order to ensure a reliable process simulation.

The numerical investigation of spindle torque for a controllable pitch propeller in feathering maneuver

Present paper studies the variation of the blade spindle torque in a controllable pitch propeller (CPP) during the feathering maneuver, which is one of the rare but most challenging propeller maneuvers in CPP operation. The knowledge of the spindle torque under different operating conditions is one of the key features for the CPP controller unit design. The aim of this study is determining the forces needed to be governed to control the blade motion of a CPP converted from a fixed pitch propeller and the scale effect on these forces. So as to obtain a realistic numerical setup, the time-dependent superposed motion of the main rotation of the propeller and the rotation of each blade around its axis is modeled using a hybrid overset/sliding mesh technique. The spindle torque values were calculated during the dynamical variation of the blade pitch in feathering maneuver, and a novel expression is recommended to non-dimensionalize the predicted spindle torque. The result revealed that the required torque values to rotate each blade during the propeller maneuver is rising up to a critical pitch angle. Further increment of the pitch angle results in lower spindle torque values. Furthermore, this critical pitch angle is inversely proportional to the propeller loading.

Novel drill geometries for dry drilling of stainless steel

One completely new geometry and two modified chip breaker geometries were designed to increase the stability and reliability of the stainless steel dry drilling process. Experiments were performed and the results of individual tools were compared with a conventional solid carbide twist drill Gühring Ratio with a diameter of 5 mm. A matrix of three feed rates (0,03–0,07 mm/rev) and three cutting speeds (20–30 m/min) was designed for the cutting conditions. Precipitation-hardenable stainless steel 17-4 PH was chosen as a workpiece. During the experiment, the values of thrust force, spindle torque, temperature of the tool, surface roughness, chips morphology and chips division were recorded and compared with the reference tool.The results showed that compared to the reference tool A, the tool C - a multipoint drill with grooves through the cutting edge achieve approximately 4 % lower values of thrust force and 10–15 % lower values of spindle torque. Tool D with a step drill geometry achieve approximately 17 % lower values of thrust force and 10–15 % lower values of spindle torque and there is no chip clogging in the flute with C and D geometries. This effect is confirmed by the fact the spindle torque basically does not increase with the increasing depth of drilling. Tool B – new designed geometry achieve approximately 15 % lower values of thrust force and similar spindle torque values as the reference drill A. Tool temperature is a very important factor when dry drilling. Compared to the reference drill A, it was possible to achieve the tool temperature reduction of 20 % with the new geometry B, as well as with the multipoint drill C reduction by 26 % and with the step drill D reduction approximately by 30 %. All the modified drills also achieved a reduction in the surface roughness of the drilled holes. By 17 %, 35 % and 48 % lower surface roughness Ra was achieved with drills B, C and D. Chip morphology was significantly different for the tested drills. Conventional twist drills A and B generated helical short chips. While C and D twist drills with divided cutting edges generated ribbon snarled chips. Thanks to the reduction of cutting forces and temperature, it is possible to stably operate the drilling process with a higher cutting speed and feed rate, which leads to an increase in the efficiency and reliability of the machining process.

Mechanical characterization of friction stir welded dissimilar aluminium alloy using Taguchi approach

Friction stir welding (FSW), a type of solid-state welding, joins two metallic workpieces, whether they are the same or different, by plastically deforming the base metal. The metallic workpieces are heated by the friction between them, which results in plastic deformation and welding. The FSW parameters, however, are what primarily determine the weldability and strength of FSW joints. The research on the FSW parameters and their impact on the quality and weldability of aluminium alloys combined with comparable and dissimilar metals by the FSW method has been previously studied, and this review work highlights that research. The majority of comparable research studies concluded that important factors, such as welding speed, rotational speed, plunge depth, spindle torque, shoulder design, base material, pin profile and tool type have a significant impact on the weldability of the aluminium joint when using the FSW method. Aluminium alloy possesses high wear and corrosion resistance; it has to be used in numerous applications such as automobile field, marine and home appliances due to its low weight. This experimental work planned to weld of dissimilar aluminium alloys such as AA7020 and AA8014 through Friction Stir Welding (FSW) process. Taguchi optimization (L9) is considered for this experimental work to examining of mechanical strength such as tensile strength, tensile strength is conducted by using of Universal testing Machine (UTM). FSW parameters are selected as tool speed (1200 rpm, 1400 rpm and 1600 rpm), welding speed (200 mm/min, 300 mm/min and 400 mm/min) and axial force (4 kN, 6 kN and 8 kN). For the tensile strength analysis, the axial force is highly influenced and the maximum tensile strength of 175 MPa is attained.

Prediction of heat generation effect on force torque and mechanical properties at varying tool rotational speed in friction stir welding using Artificial Neural Network

Friction stir welding (FSW) has played a significant role in joining aerospace alloys. During this process, the tool rotational (TRS) speed has been found to significantly affect heat generation compared to other parameters. Therefore, the study has investigated the effect of heat generation on force-torque and mechanical properties at different tool rotational speeds (TRS) in the FSW process through experimentation followed by Artificial Neural Network (ANN) technique. Further, the influence of different TRS ranging between 600 and 1800 rpm with an increment of 400 rpm on considered responses; namely thermal weld cycle, microstructure, and grain distribution in nugget zone (NZ) for 2050-T84 Al-Cu-Li alloy plates, welded using FSW were also investigated. It is observed that the vertically downward force (Z-force), longitudinal force (X-force), and spindle torque (Sp. T) decrease with increasing TRS. It is also observed an increasing (up to 1400 rpm) and then decreasing trend for tensile strength and hardness of welded samples. Moreover, the generation of frictional heat and grain size in NZ is increased with increasing TRS from 600 to 1800 rpm. However, the scanning electron microscope (SEM) micrographs of all-welded samples revealed a ductile mode of tensile fracture. Furthermore, the obtained experimental results were validated using the ANN technique. A quite better agreement has been established among the predicted outcomes from ANN with experimental results.

Development and Practical Implementation of Digital Observer for Elastic Torque of Rolling Mill Electromechanical System

The strategic initiative aimed at building “digital metallurgy” implies the introduction of diagnostic monitoring systems to trace the technical condition of critical production units. This problem is relevant for rolling mills, which provide the output and determine the quality of products of metallurgical companies. Making up monitoring systems requires the development of digital shadows and coordinate observers, the direct measurement of which is either impossible or associated with numerous difficulties. These coordinates include the spindle torque applied by the spring-transmitting torque from the motor to the rolling stand rolls. The development and research are conducted by the example of the electromechanical systems of the horizontal stand at the plate mill 5000. The stand electric drive characteristics are given, and the emergency modes that cause mechanical equipment breakdowns are analyzed that. The relevance of analyzing transient torque processes in emergency modes has been accentuated. The paper points to the shortcomings of the system for elastic torque direct measurement, including low durability due to the harsh operating conditions of precision sensors. It also highlights the need to install the measuring equipment after each spindle. The disadvantage of the previously developed observer is the function of calculating the electric drive speed derivative. This causes a decrease in noise immunity and signal recovery accuracy. The contribution of this paper is building a digital elastic torque observer that has advantages over conventional technical solutions, based on the theoretical and experimental studies. The technique for virtual observer adjustment was developed and tested in the Matlab-Simulink software package. For the first time, a comprehensive analysis was conducted for spindle elastic torques in emergency modes that caused equipment damage. An algorithm was developed for an emergency shutdown of a stand electric drive in the worst-case mode of strip retraction between work and backup rolls, due to the overlap of the strip on the roll. Further, the algorithm was tested experimentally. The criteria for diagnosing pre-emergencies was then justified. An adaptive motor-braking rate controller was developed. The developed observer and emergency braking system are in operation at the mill 5000. Long experimental research proved the efficiency of dynamic load monitoring and the reduction in the number of equipment breakdowns.

Development of High-Speed Rotation Polishing System with Slurry Confinement and Friction-State Control

An increased removal rate is required to improve the production efficiency during the polishing of ultrahard-to-process materials. The rotational speed of the polishing pad is increased to increase the removal rate. However, research has not been extensively conducted on polishing with a high-speed rotation because slurry is rarely supplied to a polishing area by the centrifugal force generated through polishing pad rotation. In this study, we developed a high-speed rotational polishing system with slurry confinement and friction-state control. The casing and spiral groove of the polishing pad were designed to confine the slurry in a polishing area, and friction-state control was adopted to maintain the spindle torque generated by friction between the pad and wafer at the target spindle torque. Based on the experiments investigating the supply efficiency, the developed polishing method can supply sufficient slurry to the polishing area by the optimized spiral groove pattern and perform polishing without slurry shortage at a high-speed pad rotation of 10000 min-1. In addition, the results of polishing experiments for a sapphire wafer revealed that friction-state control and wafer rotation could stabilize the polishing state effectively. The proposed polishing system can achieve a higher removal rate than the conventional polishing system.

The Effect of Friction Stir Welding Parameters on the Weldability of Aluminum Alloys with Similar and Dissimilar Metals: Review

The solid-state welding method known as friction stir welding (FSW) bonds two metallic work parts, whether the same or different, by plastically deforming the base metal. The frictional resistance between both metallic workpieces causes them to produce heat, which produces plastic deformation and welds them. However, the weldability and strength of FSW joints mainly depend on the FSW parameters. This review work highlights the previous research work on the FSW parameters and their effects on the weldability and quality of the aluminum alloys joined with similar and dissimilar metals through the FSW method. About 150 research studies were systematically reviewed, and the articles included data from peer-reviewed journals. It has been concluded that the key parameters, including welding speed, “rotational speed”, “plunge depth”, “spindle torque”, “shoulder design”, “base material”, “pin profile” and “tool type”, significantly affect the weldability of the aluminum joint through the FSW method. Also, the selection of these parameters is important and fundamental as they directly affect the joint. It is recommended that future work focuses on FSW for aluminum. Among these, the most essential is the application of artificial intelligence (AI) techniques to select the optimum FSW parameters for aluminum welding.

Mechanical and Microstructural Investigation on AZ91B Mg Alloys with Tool Tilt Variation by Friction Stir Welding

By modifying the angle of tilt of 2 distinct tool pin shapes, both tapered with and without threaded structures, TPT tool pin with threads and TPNT tool pin with no threads, the mechanical behaviour and microstructural attributes were examined for the joints of AZ91B alloy formed by friction stir welding. Spindle torque and unique forces operating laterally and axially (referred to as Y-force and X-force, respectively) were created at the junction of the tool and plate, which were monitored and assessed in order to know the influence of degrees of tilt. When the tool’s angle of tilt advances, torque and forces of the spindle also show an increasing trend that is important to friction stir welding. The spindle torque and Y-force produced by the TPT tool are higher than those of the TPNT tool, whereas the X-force associated with the TPT tool is less. Discrepancies in forces grow along the concurrent increase in the angle of tilt for the TPNT as well as TPT tools, exhibiting opposite behaviour. The onion ring-type structure was visualized in the threaded tool pin structure TPT due to the high flow of plasticized metal compared to TPNT tool joints, for which the onion ring shape is not visible. With the TPT tool, the joint made at a 0° angle of tilt had a peak tensile strength of 232 MPa.

Mechanistic force model for double-phased high-feed mills

Being able to predict cutting forces, torque and power in machining applications allows to check their influence on the quality of the product, to assess the feasibility of the process and to compare different operations for sustainability purposes. In this paper, the analytical development of a mechanistic model for cutting forces prediction for high-feed mills is carried out. High-feed cutters are featured by extremely low lead angles, leading to a gradual engagement of the cutter inside the workpiece. This fact prevents the mechanistic literature formulation to accurately compute the undeformed instantaneous chip section of each cutter, and thus to correctly predict the spindle torque and power. A closed analytical formulation for the mechanistic cutting force model, including an improved chip thickness formulation with variable entry and exit angles and double-phased cutter geometry, is presented. Experimental cutting tests using double-phased high-feed mills were carried out on Ti6Al4V with variable feed rate per tooth, cutting speed and axial depth of cut. The model was assessed by comparing the performances of the literature model and the developed high-feed one in the identification of specific force coefficients — SFC. The identified SFC resulted to belong to two statistically different populations. SFC 95% confidence intervals were found to be significantly narrower with respect to the literature ones. Kt,c 95% confidence intervals were equal to (1085; 1426) MPa and (970; 2423) MPa for the proposed and literature model, respectively. The validity of the proposed model was assessed in terms of mean forces, mean spindle torque and mean spindle power prediction capabilities. The Root Mean Squared Prediction Error for the proposed model resulted to be remarkably lower (15 N, 0.33 Nm, 29 W) with respect to literature model (41 N, 1.25 Nm, 120 W).

INDIRECT DRILL CONDITION MONITORING BASED ON MACHINE TOOL CONTROL SYSTEM DATA

Automatic process monitoring, including tool wear monitoring, is a key aspect of improving the energy efficiency and cost of the machining process. The tool flank wear continuously increases during drilling operations. The intensity of tool wear may vary depending on the local properties of the material and the process settings. This paper shows the potential of drill condition monitoring based on machine tool control system data, namely spindle drive current and Z slide current. The workpiece vibration measurement is used as a reference method. Correlations of various features of monitored signals are evaluated. These features are shown to depend, in general, on the instantaneous drilling depth. Among the features investigated, the RMS signal has been shown to exhibit a significant correlation with tool wear. The results were compared for two values of cutting speed. The correlation of selected features is shown to be independent of the total lifetime of the tool, thus demonstrating the attractiveness of these features for tool wear prediction. Specifically, the root mean square of the vibration and spindle torque signals strongly correlate with flank wear near the bottom of the hole while the root mean square of the drive current of the drilling axis strongly correlates with flank wear near the middle of the hole.

Investigation on the performance of a helico-axial multiphase pump under slug flow

The helico-axial multiphase pump is often used for gas-liquid mixture transportation in offshore oilfields, and slug flow is the main reason for the unstable operation of the pump. Aimed for slug flow condition, a self-designed three-stage multiphase pump is set to the object to perform unsteady simulations and fluid-structure interaction calculations, and the inlet gas void fraction (IGVF) is set from 20% to 80%. The results show that affected by the flow from the slug, the gas-liquid two-phase flow pattern in the multiphase pump changes sharply, resulting in severe fluctuations in the differential pressure, spindle torque and deformation of the multiphase pump. The gas-phase enters the first-impeller along the suction blade surface when affected by Taylor bubbles, while the second and third-stage impellers gas-phases are in the form of small air masses flow into the impeller along the pressure blade surface. The deformation trend of impeller torque, differential pressure and the main pump spindle is similar to that of trigonometric function, while the fluctuation of torque is more intense, and the shape variable of spindle increases with the inflow of liquid plug, and the maximum deformation amount increases by 10.9% at high GVF relative to IGVF.

Numerical modelling of friction stir welding of pipes: Effect of tool shoulder on mechanical property and metallurgical characterization

One of the challenges during FSW of pipe is establishing sufficient contact between the tool shoulder and the pipes to be welded. With improper contact, the torque requirement increases, which thereby increases the power consumption. The present work focuses on the demonstration of a 3D thermo-mechanical model showing the influence of tool shoulder diameter on temperature rise, plastic strain development, spindle torque, material flow occurrence, and power consumption. The model showed a good correlation with experimentally observed temperature and maximum spindle torque for different rotational speeds. It was observed from the developed model that, an increase in the shoulder diameter increases the contact area and spread of maximum temperature resulting in a wider HAZ zone. Hence, optimization of the tool shoulder diameter was necessary, and it has been addressed considering its effect on contact area, heat generation, material flow, and spindle torque. The material flow behaviour has also been studied, and it was found that a larger shoulder diameter does not produce sufficient material stirring. The welded sample has been investigated by tensile strength and microstructure analysis. The optimum tool shoulder diameter of 16 mm resulted in joint strength efficiency of 90%.

Generation of force and torque during joining of AZ91C plates by FSW under distinctive tool tilt angle and their impact on mechanical strength and micro-structure

Joint characteristics of friction stir welded AZ91C Mg alloy flat plates in terms of mechanical strength and micro-structural attributed have been investigated by varying the tool tilt angles for two distinctive tapered tool pin geometries without and with threaded structures (TP and TPWT). Spindle torque and distinctive forces acting longitudinally, vertically (termed as X and Y – force respectively) generated at the interface of the tool and flat plates were measured and analyzed to understand the impact of employed tool tilt angles. It was revealed that the spindle torque and forces relevant to FSW escalates with the increase in tool tilt angle. Spindle torque (15.1 Nm) and Y–force (6.4 kN) generated by TPWT are higher than that of TP tool (11 Nm and 2 kN), whereas X – force associated with TPWT (0.74 kN) tool was found to be lower when compared to that of the TP tool (0.98 kN). Inconsistencies in forces have escalated with a simultaneous escalation in the tool tilt angle for the TP tool and the TPWT tool has exhibited a reversed behavior. Enhanced flow of plasticized metal induced by tool pin geometry with threaded structures have contributed to the formations of onion ring type features and these structures cannot be visualized in the joints fabricated by the TP tool. The largest value of tensile strength of 227 MPa was exhibited by joint fabricated at 0° tool tilt angle using TPWT tool.