Heat transfer modelling for both workpiece and tool in the friction stir welding process: A coupled model

Abstract

In this paper, a three-dimensional transient-heat transfer model for both the tool and the workpiece in friction stir welding (FSW) has been presented. A moving coordinate is introduced to reduce the di culty of modelling the heat generation due to the movement of the tool pin. The heat transfer process of the tool and workpiece are coupled at the workpiece/tool interface. The ®nite di erence method was used in solving the energy equations. In order to improve the temperature resolution near the tool in the calculation, a non-uniform grid mesh is generated for the calculation. FSW experiments have been done to validate the modelling results. The calculated results are in good agreement with the experimental ones.

Recent advances in friction-stir welding – Process, weldment structure and properties

“…The local heat generation rate due to friction, dė f , is approximately given by [15,[25][26][27][28][29][30][31][32][33][34][35][36]:…”

Thermo-mechanical model with adaptive boundary conditions for friction stir welding of Al 6061

“…In the last decade, a number of researchers [5][6][7][8][9][10][11][12][13][14][15][16] have been working on the modeling of heat transfer during FSW. Chao and Qi [5] presented a three-dimensional heat transfer model for the workpiece assuming a constant heat flux from the tool shoulder and a trial-and-error procedure to adjust the heat input until all the calculated temperatures matched with the measured ones.…”

“…Khandkar et al [11] modeled the heat transfer to the workpiece for FSW lap welding with a moving heat source from the tool shoulder. Song and Kovacevic [12] presented a more detailed threedimensional heat transfer model for both the tool and workpiece based on a finite difference scheme to simulate the transient temperatures. The heat input from the tool pin is modeled as a moving heat source [13,14], and the heattransfer process of the tool and workpiece is indirectly coupled at the interface.…”

Evaluation of properties and FEM Model of the Friction welded mild Steel-Al6061-Alumina

“…As the friction persists, the maximum temperature drops to 224.1 °C at 0.01 seconds and decreases further down to 177.1 °C after 0.01 seconds the rod rotation the is stopped. The previous papers 21 have described the phenomena of drop in friction coefficient at temperatures close to melting point leading to a drop in heat flux value on the interfaces. This change has been considered during the modeling effort in the scope of this research.…”