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Vehicle collisions are a major concern in the modern automotive industry. To ensure the passenger safety, major focus has been given on energy absorption pattern on the crumple zone during collision, which lead to the implementation of new design of the crash box for low speed collision. The main aim of this research is optimization of the conical shaped structure based on its mean diameter, graded thickness and semi apical angle. Further, to decrease initial peak load of the conical crash box, corrugations are integrated on structure and optimized based on different parameters, such as number of corrugations, pattern of corrugation relative to both tubes and amplitude of corrugation. The concept of bi-tubular structure is proposed to improve both specific energy absorption and initial peak load during crash event. A finite element model is created to perform parametric study on corrugated conical tube based on axial load conditions at low velocity.

The surface properties have a vital role in the overall performance of the parts like brake shoe pad and other frame system. The mechanical and residual stress measurements of aluminium alloy 5083 were investigated on friction stir processed plates using the reinforcements of chromium oxide (Cr2O3) and titanium dioxide (TiO2) separately as well as combination of these powders. A comparative study was made to analyze the effects of reinforcements, tool type (cylindrical and threaded), parameters and the volume fraction of the reinforcements. The mechanical properties such as surface hardness and residual stress of the friction stir processed specimens were investigated. The experimental results shows that there was a significant increase in surface hardness (118 HRC) as well as a decrease in residual stress compare to the base metal. This study also reveals that the threaded tool with a reinforcement of Cr2O3 and TiO2 reflected better mechanical properties than the cylindrical tool.

Friction Stir Welding (FSW) is a widely used solid state welding process in which its heats metal to the below recrystallization temperature due to frictional force. FSW mostly avoids welding defects like hot cracking and porosity which are mainly occur in conventional welding techniques. In this process the combination of frictional force and the mechanical work provide heating the base metal to get defect free weld joints. Aluminium Alloys 2014 and 6061 are generally used in a wide range of automobile applications like Engine valves and tie rod, shipbuilding, and aerospace due to their high corrosion resistance, lightweight, and good mechanical properties. In the present work, aluminium alloys of AA6061 and AA2014 were effectively welded by friction stir welding technique. The tool rotational speed, travel speed, and tool profile are the important parameters in FSW process. High Speed Steel (HSS) tool with Hexagonal profile is used for this joining.