The article provides insight to the complex relationships that exist between the selected weld process parameters and the associated effects on weld responses by application of statistical analysis relating to response predictive models for Friction Hydro-Pillar Processing (FHPP). The literature review focused at obtaining the current assumptions made with regards to the relationship between FHPP and conventional Friction Welding (FW) variations. Experimental welds were produced at varying selected process parameters; motor speed, axial force, consumed length and forging time. These parameters were compared to five weld response variables through a 27-run full factorial Design of Experiment and multiple regressions. The analysis focussed on quantifying the main effects of process parameters on energy input, temperature profile, friction time, torque and consumed rate. Comparison with experimental results served to validate the effect of dominant process parameters. The process and statistical analysis are explained in detail to assist further understanding of the applied methodology and the effect of the various process parameters on weld responses presented. Results indicate that the mathematical equation based models predict the responses adequately within the limits of welding parameters used and that no single parameter solely control the weld responses during FHPP. This study provides a clearer understanding of FHPP showing that generalised conclusions, with regards to the influences of process parameters on weld responses during conventional FW, cannot be made as the effects of these inputs differ depending on the combination of levels included in a parameter set.
This paper considers the theoretical aspects required for the development of a coupled two-dimensional axi-symmetrical computational fluid dynamics (CFD) and heat transfer model for the Friction Taper Hydro-Pillar Process (FTHPP). The model applies the plasticised material movement during welding as the laminar, viscous flow of a non-Newtonian fluid, while making use of a dynamic mesh to simulate the continuous deformation of plasticised material at the friction interface. The plastic material flows through a stationary discretized flow domain not requiring a moving mesh, resulting in the Eulerian CFD approach being effective - this CFD material flow model thus avoids the requirement for re-meshing. The material properties are entered via a viscosity function used to describe the flow stress, locally dependent on material strain rate and temperature. A non-linear multiphysics problem exists as the frictional and viscous heating act as heat sources. The simulation model applies an iterative approach for coupling the plastic deformation flow analysis with the thermal analysis. Strain rate and temperature distribution of the welding material mutually affect each other, as the flow stress is temperature-dependent and the plastic work (adiabatic shear) performed during the process generates heat, in addition to heat added by friction. Isotropic temperature-dependent thermo-physical properties are required and thus incorporated into the model. A successfully coupled simulation is presented with the thermal response analysis delivering the temperature distribution through the weld for which process temperature and subsequent hardness plots are drafted. Measurements obtained from experimental welds show favourable comparison, validating computed values. The presented work attempt to show how comprehensive numerical modelling, carried out through computer simulation, can assist in the analysis of the identified process characteristics during FTHPP
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