A New Friction Law for the Modelling of Continuous Drive Friction Welding: Applications to 1045 Steel Welds

Balasubramanian, Vikram; Li, Youlin; Stotler, Tim; Crompton, J. S.; Soboyejo, Alfred; Katsube, N.; Soboyejo, W. O.

doi:10.1080/10426919908914877

Cited by 24 publications

(8 citation statements)

References 7 publications

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“…Thus, steady conditions are approached during the deformation stage. The measured temperature values are harmonious with the prior experimental studies as demonstrated (Sluzalec, 1990;Fu and Duan, 1998;Balasubramanian et al, 1999).…”

Section: Measured Temperature Valuessupporting

confidence: 87%

“…Then, the heat flow and stressstrain process at the heating stage of the friction welding were simulated, and the law of the variation of temperature, stress and the strain fields during friction welding were systematically investigated by the authors. Balasubramanian et al (1999) presented the results of a combined experimental and a numerical study of the continuous drive friction welding of the 1045 steel. A new friction law was proposed for the estimation of the apparent coefficient of the friction during direct drive friction welding.…”

Section: Introductionmentioning

confidence: 99%

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Evaluation of temperature and properties at interface of AISI 1040 steels joined by friction welding

Kuscu

Becenen

Şahin

2008

Assembly Automation

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Purpose -The purpose of this paper is to evaluate temperature and properties at interface of AISI 1040 steels joined by friction welding. Design/methodology/approach -In this study, AISI 1040 medium carbon steel was used in the experiments. Firstly, optimum parameters of the friction welding were obtained by using a statistical analysis. Later, the microstructures of the heat-affected zone are presented along with micro hardness profiles for the joints. Then, the temperature distributions are experimentally obtained in the interface of the joints that is formed during the friction welding of 1040 steels with the same geometry. This study was carried out by using thermocouples at different locations of the joint-interface. The results obtained were compared with previous studies and some comments were made about them. Findings -It was discovered that temperature had a substantial effect on the mechanical and metallurgical properties of the material.Research limitations/implications -The maximum temperature in the joint during frictional heating depends not only on the pressure, but also on the temperature gradient which depends on the rotational speed in particular. It is important to note that the measurement process was successfully accomplished in this study although it was particularly difficult to obtain temperature due to the large deformations at the interface. Future work could be concentrated on the temperature measurement of the joined materials. Practical implications -Temperature is one of the most important of all physical quantities in industry. Its measurement plays a key part in industrial quality and process control, in the efficient use of energy and other resources, in condition monitoring and in health and safety. This paper contributes to the literature about temperature measurement in welded, brazed and soldered materials. Originality/value -The main value of this paper is to contribute and fulfill the influence of the interface temperature on properties in welding of various materials that is being studied so far in the literature.

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Section: Measured Temperature Valuessupporting

confidence: 87%

Section: Introductionmentioning

confidence: 99%

Evaluation of temperature and properties at interface of AISI 1040 steels joined by friction welding

Kuscu

Becenen

Şahin

2008

Assembly Automation

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“…There are a large number of applications of steel in the automotive industry. 56 Friction welding is frequently used instead of flash welding for applications where one of the members to be joined has axial symmetry. For example, steel stampings are friction welded to the shoulder of steel rods.…”

Section: Steel Alloysmentioning

confidence: 99%

Advances in friction welding process: A review

Uday

Fauzi

Hussain

et al. 2010

Science and Technology of Welding and Joining

230

123

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Friction welding is now well established as one of the most economical and highly productive methods in joining similar and dissimilar metals. It is widely used in automotive and aerospace industrial applications. Friction welding is often the only viable alternative in this field to overcome the difficulties encountered in joining the materials with widely varying physical characteristics. This process employs a machine that is designed to convert mechanical energy into heat at the joint to weld using relative movement between workpieces, without the use of electrical energy or heat from other sources. This review deals with the fundamental understanding of the process. The focus is on the mechanism of friction welding, types of relative motions of the process, influence of parameters, heat generation in the process, understanding the deformation, microstructure and the properties of similar and dissimilar welded materials.

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“…Variable temperature dependant thermo-physical material properties would obtain more realistic results as Goldak proved that the error caused by assuming constant thermal properties was substantial [12]. The first finite element (FE) approach using both temperature-dependant material properties and a coefficient of friction to successfully predict temperature profiles and material deformation during FW of mild steel was presented by Sluzalec [13], while Balasubramanian et al applied an estimated coefficient of friction during FW of 1045 steel finding tolerable correlation when fitting the results to experimental values [14]. Bendszack et al managed to show that the material flow pattern and spiral defect formation during friction processing could be modelled and compared to the actual process [15,16].…”

Section: Introductionmentioning

confidence: 99%

Theoretical Aspects and Design of a Numerical Model for Friction Tapered Hydro-pillar Processing of Aisi4140 Steel

Zyl

Lombard²,

Hattingh³

2023

Preprint

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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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A New Friction Law for the Modelling of Continuous Drive Friction Welding: Applications to 1045 Steel Welds

Cited by 24 publications

References 7 publications

Evaluation of temperature and properties at interface of AISI 1040 steels joined by friction welding

Evaluation of temperature and properties at interface of AISI 1040 steels joined by friction welding

Advances in friction welding process: A review

Theoretical Aspects and Design of a Numerical Model for Friction Tapered Hydro-pillar Processing of Aisi4140 Steel

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