A study on the variation of forces and temperature in a friction stir welding process: A finite element approach

Jain, Rahul; Pal, Surjya K.; Singh, Shiv Brat

doi:10.1016/j.jmapro.2016.04.008

Cited by 116 publications

(41 citation statements)

References 23 publications

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“…For deep understanding of the FSW process, both experimental methods and numerical simulations can be adopted. Although some studies investigated the relationship between the traverse speed and FSW temperatures for aluminum alloys, they analyzed the temperatures at low traverse speed under around 3.5 mm/s [10] [11]. For more practical use, simulation and experimental data at higher traverse speeds should be discussed.…”

Section: Introductionmentioning

confidence: 99%

Tool Temperature and Process Modeling of Friction Stir Welding

Nakamura¹,

Obikawa²,

Yukutake³

et al. 2018

MME

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Friction stir welding (FSW) has many advantages rather than fusion welding, but details of internal phenomena during its processes have not yet been clarified. In this study, a thermo-mechanically coupled process model was developed to investigate FSW phenomena inside a tool and workpiece. As a workpiece, 6061-T6 aluminum alloy was employed. The system of FSW process model includes several thermal boundaries. Among heat flows through these boundaries, heat transfers into the exterior of the system become more sensitive to tool and workpiece temperatures than heat transfers within the system. This paper especially focused on a heat transfer coefficient at a workpiece bottom, and optimized it through experiments and finite element method (FEM) analyses. The tool temperatures during FSW were measured with a special tooling system with imbedded thermocouples within a tool. As a result, an analysis model that is able to investigate details at a wide range of traverse speeds was developed for practical high speed welding. Then, the accuracy of developed FEM model was validated with them. Finally, the temperatures and stress distribution around workpiece/tool interfaces were investigated with the developed model.

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Section: Introductionmentioning

confidence: 99%

Tool Temperature and Process Modeling of Friction Stir Welding

Nakamura¹,

Obikawa²,

Yukutake³

et al. 2018

MME

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“…a variation on these affects welding speed and rotational speed. Jain et al 2016 [6] have experimented to see that effect of axial force with time during the FSW process and A Review paper on Friction Stir Welding (FSW) also a variation of spindle torque with time. for that aluminum AA2024-T4 metal having a thickness of 5.9mm is used.…”

Section: Forces and Torquementioning

confidence: 99%

A Review paper on Friction Stir Welding (FSW)

Dewangan¹,

Chakrawarti²

2020

RJET

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Friction Stir Welding (FSW) is a new solid-state welding technique which finds application in various industries. It involves the joining of metals without any help of fusion or filler material. The joint between two metals can be formed through the combined action of frictional heating and mechanical deformation which is developed due to a rotating tool. The material that flows around the tool undergoes an extreme level of plastic deformation. Rotation generates enough friction and the friction generates sufficient heat to plastify the material. FSW is handy for welding aluminum alloys. However, interest is growing in utilizing the process in a wider range of applications that also employ non aero engine metallic materials. Therefore, it is the objective of this to provide a broad view of the capabilities of the FSW process for joining metals. This review article covers various work performed on friction stir welding, and the basics of the process and the fundamental aspects of operating an FSW. This includes a description of the different parameters that have been involved in this process. And also studied the material flow, forces, and other output responses, including defects, and strain rates that is produced.

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“…It is known that during FSW, the main input of energy into the joint is carried out by the shoulder, while the pin promotes the spread of heat and plastic deformation over the thickness of the workpiece, and also intensifies the activation process of welded surfaces [11]. The flow of material to the root of the weld creates additional compression pressure, due to which the metal is densified (forged).…”

Section: Computer Modellingmentioning

confidence: 99%

“…Recently, computer simulation has been widely used to select effective parameters of the FSW process, which can significantly reduce the cost of manufacturing an expensive special tool [6 -10]. There is a fairly large number of works devoted to computer modeling of the FSW process, but almost all of them, with rare exceptions [11][12][13], were carried out in complex software products ANSYS, ABAQUS, COSMOS FloWORK [14 -20].…”

Section: Introductionmentioning

confidence: 99%

Influence of the pin shape of the tool during friction stir welding on the process output parameters

2019

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In this paper, computer simulation of the friction stir welding (FSW) of AlMg6Mn0.6 aluminum alloy sheet blanks by means of the DEFORM-3D software package is carried out to select the optimum pin geometry based on the calculation of the displacement and speed of displacement of the material points. Pins in the shape of a cylinder and a truncated cone with the cone angles of α =10, 20, and 30° were considered. The friction coefficient of 0.5 was assumed. Instrumental steel AISI-D2 was chosen as the material for the tool. To reduce the computation time and avoid the instability of solution, the model of welded blanks was built as a single body of 3 mm thickness and 40 and 30 mm length and width, respectively. The behavior of the AlMg6Mn0.6 alloy was described using the Johnson-Cook model. The FSW process was simulated at the tool moving speed v = 2 mm / s, rotation frequency ω =1000 rpm and axial force P = 25 kN. The initial temperature of the workpiece and the tool was 20°C. When welding the blanks, the conditions of heat exchange with the environment were set. The simulation results solution have shown that the flow of the material of the workpiece depends on the shape of the pin and is different over the thickness of the workpiece. The material in the lower area of the workpiece is practically not subjected to mixing for all values of the cone angle of the pin, in contrast to the middle and upper areas of the workpiece, where the material is noticeably mixed. Of all the tips considered, the most preferred for the FSW is a pin in the form of a truncated cone with the cone angle of 10°, since it provides good mixing in the plane of the workpiece, the maximum displacement of the material towards the root of the weld, and also allows one to get the most symmetrical seam.

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A study on the variation of forces and temperature in a friction stir welding process: A finite element approach

Cited by 116 publications

References 23 publications

Tool Temperature and Process Modeling of Friction Stir Welding

Tool Temperature and Process Modeling of Friction Stir Welding

A Review paper on Friction Stir Welding (FSW)

Influence of the pin shape of the tool during friction stir welding on the process output parameters

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