Conceptual design of a friction stir welding machine for joining rails

摘要

The main objective of the project was to conceptually design a friction stir weldingudmachine for joining rails. The applicability of friction stir welding types and itsudapplication in rail joining was investigated. A number of machine concepts for joiningudrail using friction stir welding techniques were developed and a final workable conceptudwas laid out. In addition, the existing methods and machines for joining rails wereudconsidered, including arc welding, exothermic welding, flash butt welding and manualudjoining (rails joined by means of splice plate). After comparing different methods ofudjoining rails, an optimized method was selected. The capabilities of the newudconceptual machine, such as its ability to accommodate various rail profiles, wereuddemonstrated through designs and various calculations. The development costudanalysis was performed and a comparison was made with the other three methods ofudjoining rails. Consequently, it was concluded that friction stir welding concept could beudapplied in rail joining and the costs associated with it could be lowered