A study on material flow pattern in friction stir welding using finite element method

Abstract

In this article, numerical modelling of friction stir welding of copper plates is presented. The aim of this study is to implement DEFORM-3D for developing the numerical simulation. Material flow patterns are extracted using point tracking method, and mechanical/metallurgical properties of workpiece are analysed. Simulation results suggest that material particles in front of the tool pin tend to pass and settle behind the pin from the retreating side. Based on the results, a new classification of distinctive zones in the stirred zone is presented. The stir zone shape in friction stir welding is divided into five distinctive zones. In friction stir welding of copper metals, the stir zone does not lean completely towards any sides of the welding line, which was found to compare favourably with experimental observations.

Modern Manufacturing Engineering

“…In general, three categories of simulation methods exist in the literature: macro models, micro models and unified micro-macro models [114,115]. In general, three categories of simulation methods exist in the literature: macro models, micro models and unified micro-macro models [114,115].…”

“…In the macro models approach [114], the composite is considered as a single continuum or equivalent orthotropic homogeneous material (EOHM), something that can be regarded as a very rough estimation suitable for the prediction of global quantities such as the cutting forces. On the contrary, micro models treat the reinforcement, particles, fibers, or whiskers as distinct from the matrix and so, the effect of various parameters concerning these reinforcements can be investigated.…”

“…Both 2D [97,99,110,114] and 3D [101,109,124] models can be used for MMC machining studies. However, the more accurate representation of the process is performed by 3D models rather than 2D models with plain strain assumptions, when adequate computational power is available.…”

“…The metal matrix material can be modeled using: isotropic homogeneous material model [98], temperature-independent bilinear kinematic hardening material model [100], temperature-dependent material model [112], Johnson-Cook model [109,110], either elastic or plastic deformation depending on the local effective stress level [113], elastoplastic material [97,126], exponential hardening law elastoplastic [117] model. The reinforcement material can be modeled using a linear elastic material model [97,100,102,110,114,[124][125][126], i.e., using the generalized Hooke's law, or a temperature-dependent model [112]. The reinforcement material can be modeled using a linear elastic material model [97,100,102,110,114,[124][125][126], i.e., using the generalized Hooke's law, or a temperature-dependent model [112].…”

Trade-off among mechanical properties and energy consumption in multi-pass friction stir processing of Al7075 alloy employing neural network–based genetic optimization

“…5 In fact, FSP has been derived from friction stir welding (FSW) that is now regarded as an economical and technologically appropriate choice for joining similar or dissimilar metals. [6][7][8] In the simplest form, this method employs a simple steel tool consisting of a pin and a shoulder to process the material. The tool after plunging into the workpiece simultaneously rotates and travels to accomplish the task.…”