Design and Development of Jig and Fixture for Joining Thermoplastic using Bobbin Friction Stir Welding

Wong, Yui Hun (2026) Design and Development of Jig and Fixture for Joining Thermoplastic using Bobbin Friction Stir Welding. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

Text WONG YUI HUN_Full Text.pdf Restricted to Registered users only Download (2MB)

Abstract

This project focuses on the design and development of a jig and fixture specifically tailored for joining thermoplastic materials using Bobbin Friction Stir Welding (BFSW). The study addresses the research gap where most prior works emphasized tool design and process optimization while overlooking fixture development, which plays a critical role in achieving weld quality and repeatability. The main objective was to create a cost-effective, robust, and reliable clamping system that accommodates the unique thermal and mechanical behavior of thermoplastics during BFSW. The methodology involved a comprehensive literature review, conceptual and detailed jig design using CAD, selection of pure iron as the fixture material for its rigidity and thermal stability, and fabrication of the jig followed by experimental validation through welding trials on thermoplastic specimens. The results demonstrated that the fabricated jig successfully provided stability, prevented misalignment, and enabled the production of continuous welds with acceptable surface quality. Challenges were encountered, particularly in optimizing clamping torque and managing localized heat loss, as well as limitations imposed by the milling machine’s maximum spindle speed of 1320 rpm. Nevertheless, the fixture design proved effective in maintaining weld consistency, thereby contributing practical insights into fixture development for BFSW of thermoplastics and laying the foundation for further improvements in future work