Design and Development of Tool Fixture for Joining Thermoplastic using (BFSW) Bobbin Friction Stir Welding

Vejendran, Danesh (2026) Design and Development of Tool Fixture for Joining Thermoplastic using (BFSW) Bobbin Friction Stir Welding. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This project focuses on the design and development of tools and fixtures for Bobbin Friction Stir Welding (BFSW) of thermoplastics, with particular emphasis on High-Density Polyethylene (HDPE). The study began with a comprehensive review of the fundamentals of Friction Stir Welding (FSW), the bobbin tool variant, and the challenges associated with thermoplastic welding. Based on defined design requirements, several tool concepts with varying pin and shoulder geometries were modeled using Computer-Aided Design (CAD) software and fabricated from mild steel to ensure durability and machinability. A supporting fixture was also designed and constructed to provide stability and minimize distortion during welding. Experimental welding trials were performed using a milling machine at a rotational speed of 1320 rpm and a welding speed of 141.03 mm/min, successfully producing welded joints. The welds were evaluated primarily through visual inspection and surface quality assessment, which indicated the potential of BFSW to achieve consistent joining of thermoplastic materials. While the results demonstrate the feasibility of the process, challenges such as parameter control, fixture optimization, and the absence of advanced mechanical testing limited the depth of validation. This project provides a foundation for future improvements in tool design and process optimization for BFSW of thermoplastics