Modelling and simulation of FSW of polycarbonate using Finite element analysis

Meena, Shanti Lal; Murtaza, Qasim; Walia, R. S.; Niranjan, Mahendra Singh; Tyagi, Ankit

doi:10.1016/j.matpr.2021.10.260

Cited by 5 publications

(2 citation statements)

References 12 publications

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“…However, increased shoulder diameter expands the plastically deformed area due to additional material softening and heat generation [102]. A study by Meena et al [145] utilized finite element analysis to simulate the FSW of polycarbonate. The researchers observed that the highest strain rate occurs in the SZ but sharply decreases at the TMAZ.…”

Section: Strain Distributionmentioning

confidence: 99%

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A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process.

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Section: Strain Distributionmentioning

confidence: 99%

“…Additionally, an increase in tool rotational speed causes the expansion of SZ. A study by Meena et al [145] utilized finite element analysis to simulate the FSW of polycarbonate. The researchers observed that the highest strain rate occurs in the SZ but sharply decreases at the TMAZ.…”

Section: Strain Distributionmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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The impact of process parameters and pin-to-shoulder diameter ratio on the welding performance of polycarbonate in FSW

Vidakis,

Mountakis,

Moutsopoulou

et al. 2023

Int J Adv Manuf Technol

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The utilization of friction stir welding (FSW) for the joining of polymers and composites is gaining increasing recognition due to its capabilities. In this study, the weldability of 4 mm thick polycarbonate (PC) plates in FSW is examined. Statistical modeling tools were employed to investigate the effect of four control parameters, i.e., rotational speed, travel speed, weld tool shoulder, and pin diameter, on the geometrical characteristics (residual thickness) of the weld region and the mechanical performance of the weld components under flexural and tensile loads. A screening experimental procedure with an L9 Taguchi was initially performed to calibrate the control parameter levels. During the welding procedure, the temperature profiles were continuously recorded to verify the materials’ solid state. The welding efficiency of the joint was also assessed, with a 90% welding efficiency achieved in the study. The morphological characteristics of the welded zones were assessed through optical and scanning electron microscopy. The samples welded with 4 mm/min travel speed, 10 mm shoulder diameter, 1000 rpm rotational speed, and 3 mm pin diameter had the highest mechanical performance. Overall, a shoulder-to-pin diameter ratio between 2.5 and 3 achieved the best results. The findings provide valuable information for the weld performance optimization of PC sheets, which can be employed successfully in real-life uses. Graphical abstract

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The impact of process parameters and pin-to-shoulder ratio in FSW of polycarbonate: welding forces and critical quality indicators

Vidakis,

Petousis,

David

et al. 2024

Int J Adv Manuf Technol

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Friction stir welding (FSW) as a welding process for polymers is growing steadily, owing to its inheren1t advantages. The developed forces during the joining process are sensitive to the parameters used and affect the quality of the weld in terms of voids and defect formation. This study focuses on the analysis of the effects of four FSW parameters on the developed forces in joining polycarbonate (PC) 4 mm thick sheets. The porosity of the produced seams was investigated with micro-computed tomography. The dimensional deviation (top surface retreat) was also assessed with the same method. The produced seams were further inspected with microscopy. A Taguchi L9 array was formed. Analysis of variances provided prediction models for the developed forces, the porosity, the dimensional deviation, and the welding resistance rate (Fx/Fz), which were the response metrics of the study. The model’s reliability was evaluated with a confirmation run. Low travel and high rotational speeds reduce the forces in the process and lead to higher mechanical performance. Low travel speeds also reduce the porosity of the weld and affect its dimensional accuracy. The overall results offer valuable insights for optimizing the performance of FSW welds in PC sheets, which was the aim of the study (reduced porosity, dimensional deviation, etc.). The developed models ensure their successful application in real-world scenarios. Finally, the findings and the analysis were correlated with the mechanical strength of the welded PC sheets, revealing, and interpreting the mechanisms leading to higher mechanical performance of the samples. Graphical abstract

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Modelling and simulation of FSW of polycarbonate using Finite element analysis

Cited by 5 publications

References 12 publications

A Review on Friction Stir Welding/Processing: Numerical Modeling

A Review on Friction Stir Welding/Processing: Numerical Modeling

The impact of process parameters and pin-to-shoulder diameter ratio on the welding performance of polycarbonate in FSW

The impact of process parameters and pin-to-shoulder ratio in FSW of polycarbonate: welding forces and critical quality indicators

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