Finite Element Simulation of Exit Hole Filling for Friction Stir Spot Welding – A Modified Technique to Apply Practically

Malik, Vinayak; Sanjeev, N.K.; Hebbar, H. Suresh; Kailas, Satish V.

doi:10.1016/j.proeng.2014.12.405

Cited by 16 publications

(7 citation statements)

References 13 publications

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“…To assess the degree of compliance of the numerical model with the real welding process, the cross section of the weld structure was first analysed by comparing it with the cross section of the real joint. The views of the cross section of numerically predicted material flow in the weld and the (7) q r = r (T 4 r − T 4 ∞ ) cross section of the fabricated weld are shown in Fig. 9a, b, respectively.…”

Section: Characterisation Of the Weld Zonementioning

confidence: 99%

“…A 3D FE model of welding AA6060 T6 aluminium alloy sheets has been built in the Deform program considering a rigid-plastic material model. Malik et al [7] developed a three-dimensional FE-based model of FSSW using the commercial Deform/Implicit code to select appropriate welding parameters to fill an exit hole in the weld. According to the conclusions provided, the process parameters obtained have the potential to reduce the number of experiments.…”

Section: Introductionmentioning

confidence: 99%

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A fully coupled thermo-mechanical numerical modelling of the refill friction stir spot welding process in Alclad 7075-T6 aluminium alloy sheets

Kubit

Trzepieciński

2020

Archiv.Civ.Mech.Eng

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Refill friction stir spot welding (RFSSW) is a solid state joining technology that has the potential to replace processes such as the open-air fusion bonding technique and rivet technology in aerospace applications. Selection of proper RFSSW parameters is a crucial task which is important to ensure the mechanical strength of the joint. The aim of this paper is to undertake numerical modelling of the RFSSW process to understand the physics of the welding process, which involves large deformations, complex contact conditions and steep temperature gradients. Three-dimensional fully coupled thermo-mechanical models of RFSSW joints between Alclad 7075-T6 aluminium alloy sheets have been built in the finite-element-based program Simufact Forming. The simulation results included the temperature distribution and the stress and strain distributions in the overlap joint. The results of numerical computations have been compared with experimental ones. The numerical model was able to predict the mechanics of material flow during the joining of sheets of Alclad aluminium alloys using RFSSW. The predictions of the temperature gradient in the weld zone were in good agreement with the temperature measured experimentally. The numerical models that have been built are capable of simulating RFSSW to reduce the number of experiments required to set optimal welding parameters.

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Section: Characterisation Of the Weld Zonementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A fully coupled thermo-mechanical numerical modelling of the refill friction stir spot welding process in Alclad 7075-T6 aluminium alloy sheets

Kubit

Trzepieciński

2020

Archiv.Civ.Mech.Eng

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“…The material flow is enhanced with the increase of rotational speed and maximum flow velocities were observed near the shoulder outer periphery region. Malik et al [ 21 ] used DEFORM-3D for refilling the exit hole in a three-stage operation using diverse types of non-consumable tools in each operation. The refilling of the exit hole was accomplished, but no quantitative results were presented.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Analysis of Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets

et al. 2021

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The refill friction stir spot welding (refill FSSW) process is a solid-state joining process to produce welds without a keyhole in spot joint configuration. This study presents a thermo-mechanical model of refill FSSW, validated on experimental thermal cycles for thin aluminium sheets of AA7075-T6. The temperatures in the weld centre and outside the welding zone at selected points were recorded using K-type thermocouples for more accurate validation of the thermo-mechanical model. A thermo-mechanical three-dimensional refill FSSW model was built using DEFORM-3D. The temperature results from the refill FSSW numerical model are in good agreement with the experimental results. Three-dimensional material flow during plunging and refilling stages is analysed in detail and compared to experimental microstructure and hardness results. The simulation results obtained from the refill FSSW model correspond well with the experimental results. The developed 3D numerical model is able to predict the thermal cycles, material flow, strain, and strain rates which are key factors for the identification and characterization of zones as well for determining joint quality.

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“…Increased productivity with better quality, ease of automation, leeway to produce continuous linear welds and the ability to weld almost any thermoplastics are considered as the advantages of this process (Malik et al , 2020; Vijendra and Sharma, 2015). Compared to conventional welding, FSW offers great advantages, as there is no melting involved, fewer defects with a better weld quality, low energy requirement and no consumables (Kumar et al , 2019; Malik et al , 2014; Quintana and Silveira, 2017). From an environmental aspect, there is no/reduced material wastage, no radiation or emission of harmful gases (Eslami et al , 2015).…”

Section: Welding Of Three-dimensional Printed Partsmentioning

confidence: 99%

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

Tiwary

Arunkumar

Malik³

2021

RPJ

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Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume of a commercially available 3D printer is one inherent constraint, which holds its acceptability by the manufacturing business leaders. This paper aims to address the issue by presenting a novel classification of the possible ways by which 3D-printed parts can be joined or welded to achieve a bigger-sized component. Design/methodology/approach A two-step literature review is performed. The first section deals with the past and present research studies related to adhesive bonding, mechanical interlocking, fastening and big area additive manufacturing of 3D printed thermoplastics. In the second section, the literature searches were focused on retrieving details related to the welding of 3D printed parts, specifically related to friction stir welding, friction (spin) welding, microwave and ultrasonic welding. Findings The key findings of this review study comprise the present up-to-date research developments, pros, cons, critical challenges and the future research directions related to each of the joining/welding techniques. After reading this study, a better understanding of how and which joining/welding technique to be applied to obtain a bigger volume 3D printed component will be acquired. Practical implications The study provides a realistic approach for the joining of 3D printed parts made by the fused deposition modeling (FDM) technique. Originality/value This is the first literature review related to joining or welding of FDM-3D printed parts helping the 3D printing fraternity and researchers, thus increasing the acceptability of low-cost FDM printers by the manufacturing business leaders.

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Finite Element Simulation of Exit Hole Filling for Friction Stir Spot Welding – A Modified Technique to Apply Practically

Cited by 16 publications

References 13 publications

A fully coupled thermo-mechanical numerical modelling of the refill friction stir spot welding process in Alclad 7075-T6 aluminium alloy sheets

A fully coupled thermo-mechanical numerical modelling of the refill friction stir spot welding process in Alclad 7075-T6 aluminium alloy sheets

Experimental and Numerical Analysis of Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

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