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This study presents a systematic experimental analysis of vibration responses in a planetary gearbox (type A2000) under both undamaged and artificially induced fault conditions. The primary aim was to identify specific frequency-domain signatures of various types and severities of gear defects—such as pitting on the flanks of gear teeth, missing teeth, unbalance of the carrier, and damage to the ring gear—through spectral analysis of vibration signals. Measurements were conducted in both loaded and unloaded states using non-contact torque sensors and a multi-channel diagnostic system (SKF IMx-S) with tri-axial accelerometers. The results demonstrate a strong correlation between the severity of gear damage and the amplitude and structure of sidebands around the gear mesh frequencies. Notably, the presence of pitting consistently increased the sideband amplitudes, while unbalance induced distinct harmonics in the frequency spectrum. Damage to the ring gear and central gear exhibited overlapping features but were distinguishable in the acceleration envelope spectrum. The findings provide a foundation for the early-stage identification of gearbox faults and highlight the potential for deploying automated diagnostic systems in industrial applications. Future work will focus on real-time AI-based detection methods and application of the results in industrial environments such as Continental and U.S. Steel.

This paper investigates the replacement of a conventional steel coil spring with a composite disc spring with the aim of minimizing its weight. Simulation in the CAD system Siemens NX 12 was used to determine the composite disc spring’s behavior. The regression functions were stated based on the numerical simulation. Based on the regression functions the solution with the minimum weight was found using software programmed in Matlab. The prototype discs were manufactured from carbon fibre prepreg. Their load-deflection characteristics were tested and compared with the designed values. The experimental results show that using this solution reduces the weight by about 30% in this case.

There are many drawbacks and inconveniences in the application of human power in the energy meter calibration line. In order to achieve a standardized level of operation and to improve the efficiency and quality of the automated meter testing line, this paper applies the intelligent inspection robot to the automated meter testing line and discusses the key technologies involved. Based on the texture characteristics of the screws on the energy meter cover, a screw coordinate positioning method based on the texture center of gravity method is designed as a machine vision technique for intelligent inspection robots. Based on the feedforward controller transfer function and feedback system open-loop transfer function, combined with PI controller, a feedforward-feedback composite servo position control strategy is designed to complete the release action of the robot end controller. Pressure sensor on the robot end claw controller, integrated servo drive with current sensor. The Kalman filter method of static estimation is used to fuse and process multi-source data information to realize the grasping action of the robot end controller. The test results of the key technical performance and economic and time benefits of the robot show that the recognition success rate and grasping success rate of the robot for energy meters are as high as 100%, and it takes a total of 54s to complete each grasping and releasing action. The maximum error in each direction is 4.9mm, 5.2mm and 5.1mm respectively, and the maximum error in angle is only 1.25 degrees. The working manpower is reduced by as much as 93.16%, the average expenditure of inspection cost is only 1.24 yuan, and the floor space is reduced to 700 square meters. In summary, the study can ensure a high level of consistency in the quality of energy meters, improve the efficiency of calibration and production, and create greater economic benefits while providing a solid technical guarantee for the large-scale construction and stable and reliable operation of the power grid.

Cast iron with nodular graphite is one of the most important structural materials that exhibit really good mechanical properties already in the as-cast condition. Nowadays, cast iron with nodular graphite is used in many areas of the manufacturing industry, the most widespread being in the engineering and automotive industries. The applicability of this material for construction purposes is mainly due to its mechanical properties, which are close to those of steel, but the production cost of cast iron is lower. This experiment was aimed at optimizing the production of ductile iron castings in the casting pits so that the foundry could produce ductile iron castings in the casting pits. Therefore, the optimization of the moulding compound database material was carried out in numerical simulation and at the same time, the heat transfer measurement of the foundry sand mould was carried out.

Optimising the mechanical properties required for biomedical applications is something that porous Ti-6Al-4V structures offer the opportunity to do. Triply periodic minimal surface (TPMS) structures, such as the Diamond and Gyroid structures, provide interconnected pores that can be used to adjust strength, stiffness and deformation. The mechanical behaviour of these two architectures under compressive and bending loads is compared in this study, with the use of additively manufactured samples. The results demonstrate that pore geometry significantly impacts mechanical behaviour. Diamond structures exhibit higher stiffness and strength, whereas Gyroid structures provide a more isotropic and flexible response. These findings emphasise the importance of architecture when designing implants and other components for which optimised mechanical properties and geometry are essential.

longitudinal externally splined parts have garnered increasing attention due to their critical role in power transmission across various industrial applications. This study explores the use of the internally rotating ballizing technique for manufacturing these components. The process was analyzed both experimentally and numerically through a mathematical model. The experimental investigation focused on key process parameters, including die rotational speed (50, 63, 80, 100, 125, 160, 200, 250, and 315 rpm), axial feed rate (0.13, 0.15, 0.18, and 0.21 mm/rev), interference between the balls and the tubular sample (cross in-feed: 2.5, 3.5, 4.5 and 5.5 mm), and initial tube thickness (4, 5, 6 and 7 mm). The study assessed the influence of these variables on the forming load and the quality of the produced longitudinal externally splined sleeves. A numerical model was developed to predict forming loads, and the findings indicated that these parameters significantly affect both (forming load and filling ratio). The optimal values for these variables were identified, and the numerical results showed a strong correlation with experimental findings. Keywords: Externally Splined Sleeves, rotary Ballizing Process, Numerical method, Experimental Study and forming load.

This study centers on 7B50 aluminium alloy. The intention is to reduce the pre-treatment and post-treatment times of the shot peening model. By comparing and analyzing different process parameters, the best combination of peening solutions can be obtained. The pre-processing is implemented through a GUI interactive interface. Post-processing is carried out by using Python for secondary development in ABAQUS. Orthogonal test method is employed for post-processing analysis of shot peening simulations under various process conditions. The results are evaluated by using a weighted composite scoring method to determine the depth of the residual compressive stress layer on the workpiece surface, the surface residual compressive stress, and the extreme deviation of the maximum residual compressive stress value after shot peening. The combined influence degree of shot peening process parameters such as impact speed, projectile diameter and impact angle is determined. The optimal combination of shot peening process parameters is analyzed and verified through simulation.

In a vertical impact crusher, material particles undergo multiple impact collisions and eventually break due to accumulated damage. In order to further study the crushing mechanism of the crusher, a cumulative damage model of material particles under re-peated impact was established. Firstly, a crushing model is established based on the specific fracture energy, reflecting material particles' cumulative damage and crushing process. Then, the simulation model of the crushing system of the vertical shaft impact crusher is established. And by simulating the crushing process of limestone particles in a crusher, it reveals that the crushing of particles is essentially due to the crushing that occurs as a result of multiple cumulative impacts. Next, the simulation model is used to simulate and analyze the rotor's power and particle size distribution of crushed products of limestone, iron ore, and copper ore during crushing. The reliability of the simulation model is experimentally validated. Finally, the simulation analyzed the in-fluence of the diameter and speed of the crusher rotor, as well as the mixed feeding of various materials, on the rotor power and material crushing effect. The results show that the particle size distribution curves of three types of crushed products, including limestone, have a high degree of agreement between simulation and experiment. Fur-thermore, the simulation values of rotor power and specific power consumption fit well with the experimental values, verifying the reliability of the simulation model. As the rotor diameter and rotor speed increase, the rotor power and sand production rate gradually increase. And the increase in rotor power is much greater than the increase in sand production rate. When the feed is a mixture of multiple materials, the rotor power increases approximately linearly with the increase of the proportion of high hardness materials in the feed, while the yield of fine particles in the crushed product decreases with the increase of the proportion of high hardness materials in the feed.

The magnitude of a locomotive's traction and braking forces is directly related to its adhesive mass, which largely determines its tractive and braking characteristics. Therefore, an important task is to maximize the utilization of the locomotive's adhesive mass. The degree of adhesive mass utilization is determined by more factors and is quantitatively characterized by the Adhesive Mass Utilization Coeffi-cient (AMUC). One of the ways to increase the AMUC is to improve the locomotive's lever-type brake transmission. In braking mode, it interacts with the wheelsets and the bogie frame and may block the operation of the first stage of the suspension system. This research presents the results of a mathematical model-based study of the influence of certain parameters of the lever brake transmission on the utilisation of locomotive adhesive mass in braking mode. The calculations were carried out for various values of the vertical stiffness of the brake transmission. The results indicate that the distribution of vertical loads across the locomotive's wheelsets in braking mode significantly depends on the vertical stiffness of the brake transmission.

Spin coating is basic method for preparation of thin polymer resist layer (polycarbonate) or colloidal solution (grapheme oxide in alcohol). This method main benefits are speed of preparation and the possibility of tuning final coating of silicon sample by variations of parameters such as the speed of rotation, time and the amount of the solution. To find out the exact graphene oxide layer spin coating process a planned experiment was designed. The greatest coverage of the silicon sample grapheme was obtained by studying the data obtained from electron microscopy (SEM) and light microscopy (LM) of the spin coating input conditions

Article deals with analysis on influence of post-process settings profiles in the Polyworks software and its influence on measuring bias (difference between average surface profile deviation and artifact reference value) and standard deviation of measured data. The comparison was evaluated on glossy artifacts with freeform surfaces. Setting with least bias and standard deviation was than used to evaluate repeatability and systematic measurement error and minimum tolerance bandwidth Tmin according to VDA 5 and MSA 4, respectively for three conceptions of laser scanning technologies available on today’s market. Cartesian CMM LK Altera S with laser scanner Nikon LC15Dx (automated technology), Measuring arm Nikon MCAx S30 with laser scanner Nikon H120 (manual technology) and optically tracked handheld device Metronor M-Scan with laser scanner Nikon H120 (manual technology). The conclusions of the study can serve as a guide in technology selection for reverse engineering input data acquisition. Subsequently, the optimal parameters of the post-process settings (for glossy surfaces) in the Polyworks software are listed.

The paper focuses on the application of machine learning techniques and optimization algorithms in predictions and controls of grinding temperature variations. The major thrust of investigation has been on how the different input conditions such as feed, depth of cut, and cooling conditions influence grinding temperatures and the effectiveness of these conditions on the control of their thermal effects. Three machine learning models: Random Forest (RF), Gradient Boosting (GB), and Artificial Neural Networks (ANN) were then used to develop prediction models for the grinding temperature on both face and shoulder of the workpiece. Out of all the models, RF achieved a much higher R² score of 0.96 as compared to both GB and ANN, indicating its greater predictive performance. Furthermore, Bayesian optimization and genetic algorithms were employed in model optimization and grind parameters and cooling condition optimization to avoid damages caused due to temperature. MQL has been found to be highly superior to the inefficient dry cooling methods in terms of achieving lower grinding temperatures and, therefore, seems to be most suited as an eco-friendly yet practical cooling solution as based on this comparison. Altogether, these research findings indicate that AI-based techniques and traditional optimization methods can lead to much better grinding in terms of efficiency and energy consumption, as well as surface quality, and assist towards greener manufacturing altogether.

Marine ships engines are kind of huge diesel engines. In fact, the manner of controlling the speed of a ship can impact badly on the financial matters of the machinery operation. Thus, controlling the speed of the marine engines can avoid ships to face dangerous accidents. In purpose to prevent such kind of damages, marine systems simulator have been widely used as numerical tools. In fact, the simulation of speed control systems makes it possible to render the process of controlling the speed of an engine economical and eliminates many risks. In this article, we first present a mathematical formulation to illustrate the rotational velocity process of a ship model's marine diesel engine as well as its PID controller. Secondly, we introduce a novel python's marine simulator which includes a PID controller to govern marine ship model's engines and we compare its results with another PID diesel engine speed controller that we modelled, designed and simulated via Matlab/Simulink. Results of scenarios and experiences which we carried out have shown that the response of the speed control system when using python can be accurate and close to the one of Matlab/Simulink.

This study examines the effect of accelerated weathering on the mechanical and viscoelastic properties of thermoplastics produced by fused filament fabrication (FFF). Three polymers, acrylonitrile styrene acrylate (ASA), polyethylene terephthalate glycol (PETG), and polylactic acid (PLA), were subjected to alternating UV radiation and condensation cycles in a QUV chamber simulating environmental exposure. Tensile testing and dynamic mechanical analysis (DMA) were used to evaluate the changes in strength, stiffness, and glass-transition behavior. The results revealed distinct responses depending on the polymer structure. ASA maintained its ductility and even showed improved strength, confirming high UV resistance. PETG exhibited a moderate decrease in strength with negligible change in elongation, indicating partial photo-oxidation but stable viscoelastic behavior. PLA demonstrated the most significant stiffening and a noticeable upward shift of the glass-transition temperature due to crystallization and physical aging. Overall, short-term QUV exposure acted as a conditioning process, enhancing the thermal and structural stability of the tested FFF-printed polymers.

This research focused on the production of brake pads reinforced with bronze fibers to see the anticipated performance principles for braking systems. Three unique amalgamated formulations, labeled BRZ-I, BRZ-II, and BRZ-III, were set by varying the bronze fiber content to 5%, 10%, and 15% by weight. The tribological characteristics of these composites were systematically evaluated to determine their effectiveness. Traditional manufacturing processes were used in developing the brake pad. Various properties such as physical, chemical, mechanical and tribological possessions were assessed by means of chase test rig. Worn-superficial examination stayed carried out by using chase test rig. Base results it was evident that the 10 weight percentages of the bronze fibers showed better physical, chemical, mechanical and tribological properties. Chase test results confirmed that the composite brake pad developed with 10 weight percentages of bronze showed better results at higher pressure-speed conditions than others due to better plateau formation and less wear rate. The results obtained after performing various performances such as physical, chemical, mechanical and tribological properties concluded that the bronze fiber possessed lesser wear and stable coefficient of friction.

This article deals with the experimental investigation of the influence of tire pressure on fuel consumption and tire life in passenger cars. Using laboratory and real-world operational measurements, the dependence between tire pressure and temperature, contact patch size, tread wear, and changes in driving characteristics was analyzed. The results show that even slight deviations from the prescribed pressure can lead to increased fuel consumption, shortened tire life, and reduced driving comfort and safety. The article also draws attention to the insufficient use of pressure monitoring systems in practice and points to the economic and ecological impacts of underinflation. The experimental data are supplemented with graphs and tables that demonstrate the influence of pressure on tire behavior during driving.

Externally toothed components have a very crucial and essential role in all areas of production and manufacturing because they function as away of transmitting motion, energy, and power in all indus-trial applications, such asmodes of transportation, aviation, aerospace, equipment, and operating machines like lathes and milling. All machines have a gear box. Therefore, it is receiving increasing attention. This research presents a new multi-stage rotary ballizing technology for producing toothed parts in one stroke. This process has been investigated experimentally. The parameters that were ex-amined experimentally was at the optimal conditions for single stage ballizing were: die rotation speed of 315 rpm; Axial feed rate, 0.13, mm/rev; The interference (cross in-feed) between the balls and the tubular specimen of 5.5 and 6.5 mm is formed by three stages of ball forming of graduated outer diameters and fixed on a single mandrel; Initial tube thickness is 7 and 8 mm. The effect of these parameters on the forming load, filling ratio and quality of the formed part was studied. The finding sindicated that the seideal variables influence the forming load, tooth filling proportion, and product quality. Experimental results proved the success of this novel technique to form toothed tubular components

This article is dedicated to exploring the potential enhancement of mechanical properties, such as hardness and tensile strength, in selected Al-Si alloys (AlSi7Mg0.3, AlSi7Cu4, and Al-Si10.5Cu1.2Mn0.8Ni1.2). High-melting-point elements, such as chromium and molybdenum, are rarely utilized as additives in Al-Si alloys. However, the article demonstrates the feasibility of improving the mechanical properties of these alloys through the addition of high-melting-point elements. High-melting-point metals, often referred to as refractory metals, typically have melting points above 2000 degrees Celsius. Common refractory metals include tungsten, molybdenum, tantalum, niobium, rhenium, and others. These metals exhibit excellent mechanical properties at elevated temperatures and often possess high density and good corrosion resistance. All casts were made using by gravity casting with different heat treatment conditions at 740 °C. The microstructures, hardness, microhard-ness and tensile strenght of the samples were analyzed. Hardness measurements were conducted using two types of hardness testers according to ČSN EN ISO 6506-1 for the Brinell hardness test method and ČSN EN ISO 6507-1 for the Vickers hardness test method. A static tensile test was performed on a universal testing machine, Inspekt 100, in accordance with the standard ČSN EN ISO 6892-1. The measured data demonstrated that high-melting-point metals affect each alloy differently. In some alloys, mechanical properties improved after heat treatment, while in others, a significant deterioration was observed, particularly in tensile strength.

The use of modern production techniques such as 3D printing brings new requirements for shaping ma-chine parts. In the case of the production of the runner blades of Kaplan micro-turbine using 3D printing technology from plastic, the emphasis is on the mechanical properties of the blade and hydraulic proper-ties of the entire turbine. Achieving the required parameters is conditioned by finding a suitable shape of the runner. Therefore the design, virtual testing, optimization and evaluation process is automated. The paper describes the whole process where virtual testing of hydraulic parameters is performed by CFD simulations, and the methods of genetic algorithms are used for optimization. Selected final geometrical shapes of the blade are subjected to a more detailed analysis of hydraulic parameters in the wider oper-ating range and also to the strength analysis.

The article is focused on the investigation of the impact of the implementation of mechanization into the welding workplace, for the production of cylinders from austenitic X5CrNi18 10 chromium nickel steel. The welds are assembled into a production line for the processing of puff pastry. In addition to the technical improvement of the process and the verification of the sufficient quality of the welds, calculations were used to prove that after the implementation of the change, there was a significant reduction in the production time. By introducing a higher level of mechanization and necessary technological changes, the production time was reduced by up to half, compared with the original technological procedure, including an increase in quality parameters and it led to a reduction in the production costs of the welding workplace. A significant consequence of the proposed change was connected with its impact on workplace safety.

This paper examines the detection of internal defects in composite specimens composed of Onyx, a material featuring a nylon matrix reinforced with chopped carbon fibers. Artificial defects, in the form of flat-bottom holes of various geometries, were intentionally introduced during the additive manufac-turing process. The primary objective is to determine the depth detection capabilities of ultrasound by varying the excitation frequency and determining whether these defects remain identifiable at different subsurface levels. Ultrasonic lock-in thermography is utilized to excite specimens. As the frequency is modified, the depth of wave propagation also changes, a phenomenon well established in homogene-ous materials. However, the heterogeneous nature of Onyx introduces complexities into wave propa-gation. The recorded thermographic data are processed in MATLAB to calculate contrast ratio values, enabling a quantitative comparison of defect detectability for different defect geometries.

The presented article deals with the application of Reverse Engineering and Rapid Prototyp-ing processes in the development process in the automotive industry. In our case, we will focus on the design of the exterior rear view mirror. We obtained the information about the shape and as well as the data used to model the part in a virtual CAD computer environment by scanning it with a Leica laser scanner. The obtained point cloud was imported into CATIA V5 software, which is often used in the automotive industry. In the CATIA software modules, section curves were translated into cloud points. Based on these curves, free shaped surfaces of the mirror body and its holder on the car door were created. After creating the mirror body-mirror mount assembly, print data of these parts were generated for production by Rapid Prototyping technology. The printing method based on ABS material using the FDM (Fused Deposition Modeling) method was chosen.

This article deals with the calculation of pressure vessels for beer maturation using analytical calcula-tion according to ČSN standards and with the help of commercial software PVESS. The article pre-sents commonly used procedures in the design of pressure vessels, resp. vessels for use in the brewing industry in the assembly of pressure vessels stacked on top of each other. The article describes the main parts of the brewery tanks, including the procedure for their design. The choice of materials used, the choice of basic dimensions of pressure vessels was determined in the work. The tank vessel is made of stainless steel 1.4301 or 1.4541. The advantages of this material in the brewing industry are also presented. From the given input parameters, a control calculation of the strength of pressure vessels was performed. The result of the work was the verification of the calculation, finding out the deviations of the measurements using mathematical software with a common calculation according to the valid standards for the calculation of pressure vessels.

Quality design is necessary prerequisite for correct and safe operation of all mechanical devices. This design has to consider all simulations and calculations. All boundary conditions have to be involved in this design. Ignorance of some of them can lead to overloading of structure or to the destruction of whole device, as shown in the example in this paper. Following design solutions can improve these mistakes, but this is technically difficult and costs are much higher. This article deals with calculations of air piping and with supporting structures for this system. This example from praxis shows importance both simple calculations and advanced structural simulations. Benefits of advanced FEM simulations are shown clearly using described structure. These benefits can be applied on all mechanical systems.

A crane bridge is a dominant component of all bridge crane. It is imperative to pay attention on its strength features and go through a strength analysis. The introductory part of this paper points out characteristics of a bridge crane, mainly a crane bridge and materials used to produce the crane bridge, namely S235 structural steel. The paper set out the strength analysis of the main girder of a single girder bridge crane model in the means of comparing analytical and numerical solutions. The calculations take into account the load of the main beam in its centre according to the standard STN 27 0103. The bridge crane model is designed for a 500 kg load carrying capacity. The numerical solu-tions are represented by finite element method (FEM) analysis in Ansys software. The intention is to determine the deformation of the main girder depending on the weight of a load and a hoist, to de-termine the maximum deflection and resulted bending stress. Furthermore, one of the purposes is to create the precise 3D CAD model of the main girder. The 3D CAD software Catia V5 was used to design the bridge crane model. The strength analysis of the main girder of IPE 100 profile was performed by the FEM analysis using the Ansys software and by analytical calculations. The results ob-tained by the computing software Ansys were only slightly smaller in comparison with the analytical calculations. Results obtained by Ansys can be considered as more accurate. It can be concluded, such the designed and strength-checked main girder can be in the future put into a production.

This paper aims at the problems of poor motion continuity and abrupt acceleration of small diameter deep well rescue robot in the process of motion characteristics analysis. According to the movement characteristics and structural forms of the grasping mechanism and bracket mechanism of the deep well rescue robot, the finite element analysis of the key mechanism is carried out based on Hyperworks-Optistruct solver, according to the analysis results, the specific parameters to be optimized are obtained. And the topology optimization of the key mechanism is carried out, the optimal design scheme of clamping mechanism and bracket mechanism of deep well rescue robot are obtained. The optimization results show that on the premise of meeting the strength requirements, the grid density distribution law is obtained. According to the variation law of lightweight curve, the overall weight of grasping mechanism and bracket mechanism decreases obviously. The whole optimization process is completed and the final optimization result is obtained.

Article deals with design of jig for welding of rail-borne door system on the basis of model and drawing of window frame. Using this jig is ensured right setting and reliable clamping of two bent profiles. By welding of these profiles is made a window frame of automatic door systems for rail-bornes. TIG method is used for welding. Article describes and explains setting and clamping of window frame into jig. Design of control jig for window frames of similar type is embodied in text too. Control jig helps by dimension measurement of window frames.

Modular fixture is conventionally designed less concerning the detailed specifications of machine tool. A little of literatures involve the effectively application to the existing CAD systems in CAFD (computer-aided fixture design). The determination of the validity of modular fixture during NC machining lacks for a practical method. This paper put forward that: Firstly, the feature-model repository of elements of modular fixture can be built in CAD packages; the design of modular fixture in NC machining should be accomplished under the concept of NC Manufacturing System (NMS); the Post-NC verification can be applied to check the performance of modular fixture applied in NC machining. Part 1 of the paper focuses on the feature-model repository of the modular-fixture elements. The other jobs will be introduced in the Part 2.

The Edge Localized Mode coil is the key component to prohibit the phenomena of disruptive instability occur-ring in the edge of Tokamak plasma. And the coil is made of Stainless Steel Jacketed Mineral Insulated Con-ductors. The different pieces of conductor are connected by joints. During the normal operation of Tokamak device, the joint will be shocked by electromagnetic and thermal loads. Thus, it is necessary to perform the mechanical analysis to verify whether or not the ELM joint has sufficient safety margin to resist the impact of coupling field. In order to obtain the load boundary condition for mechanical analysis, the electromagnetic and thermal analysis are launched first. Then the temperature and electromagnetic force density are inserted into the mechanical analysis model. And the equivalent stress is calculated. The analysis results indicate there is stress intensity at the component of supporting rail. To mitigate the stress intensity, the local structural optimi-zation design is employed. Finally, the stress evaluation is carried out based on analytical design. The assess-ment results demonstrate the optimized model has sufficient safety margin to withstand the combined action of multiple loads.

Friction stir spot welding (FSSW) is an alternative joining process mostly suitable for joining dissimilar sheets or when conventional spot welding is not applicable. In this paper, lap joint of 2 mm thickness AA1050 aluminum sheets and C10100 copper sheets using different process parameters and fixed tool geometry were investigated. Experimental plan is designed according to response surface methodology (RSM) where: tool rotation speed, plunge depth and dwell time vary between 500 and 2500 rpm, 2.1 and 3.7 mm and 0 and 8 s respectively. The main affecting and interaction process parameters are evaluated using analysis of variance (ANOVA) methodolgy. Mathematical models describing the relationship between welding parameters and shear failure load (SFL) are developed and the optimal FSSW parameters are specified. Design expert software is used for optimization of friction stir spot welding process parameters using response graphs and contour plots. With 95% confidence level, shear failure load of the dissimilar Al 1050—Cu 10100 joints are predicted using the developed empirical relations. It is found that the optimal results of the SFL is close to the optimal solution obtained from the mathematical model with less than 4% discrepancy.