Modelling of Friction Stir Processing with in Process Cooling Using Computational Fluid Dynamics Analysis

Albakri, A.N.; Aljoaba, S. Z.; Khraisheh, Marwan

doi:10.1007/978-3-642-20183-7_15

Cited by 10 publications

(5 citation statements)

References 16 publications

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“…Heat generation at tool-tip curved surface Upon adding equations ( 25)-( 27), we get the total heat generated by the tool described through equation (28):…”

Section: Inclinedmentioning

confidence: 99%

“…For a flat shoulder, 0 a = °As derived by Schmidt et al [36], the above analytical model contains the term of contact shear stress, contact t as seen in equation (28). The value of this shear stress was understood to have varying values depending upon the type of tool and material matrix contact.…”

Section: Inclinedmentioning

confidence: 99%

“…The plasticity of the material was modelled by using the Johnson-Cook material model, while Coulomb's frictional law governed the frictional contact between the workpiece plates and the tool. Albakri et al [28] studied the effect of the presence of a cooling channel on the flow stress, grain size and temperature distribution of the friction stir welded specimen. The analysis was done using a commercially available computational fluid dynamics software of Star CCM+.…”

Section: Introductionmentioning

confidence: 99%

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Numerically modelled study of the plunge stage in friction stir spot welding using multi-tiered mesh partitions

2021

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Friction stir spot welding is a solid-state joining process that has attracted significant attention particularly in the field of joining of lightweight, low melting alloys. These materials include alloys of Aluminium and Magnesium amongst many others which are of great importance to the aerospace and the automobile industries. The friction stir spot welding is a complex thermo-mechanical multiphysics phenomenon and is currently a field of intense research. The motivation of the current study is to understand this complex behaviour of the joining process by simulating it in the ABAQUS CAE environment. In the friction stir spot joining technique, the plunge stage is identified as the critical stage of operation as it involves a highly transient and dynamic zone for material and temperature flows. The plunge stage was studied in detail using the finite element based model. The plasticity of the material was simulated by the Johnson-Cook material model while the frictional heat generation was captured by applying a penalty-based frictional contact between the rotating tool and the workpiece contact surfaces. Considering the reasonable assumptions made, the results obtained by the numerical simulation model were found to agree with the past experimental and numerically modelled studies.

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“…Heat generation at tool-tip curved surface Upon adding equations ( 25)-( 27), we get the total heat generated by the tool described through equation (28):…”

Section: Inclinedmentioning

confidence: 99%

Section: Inclinedmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Numerically modelled study of the plunge stage in friction stir spot welding using multi-tiered mesh partitions

2021

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“…In terms of considering the effect of cooling via numerical models, some endeavors have been done. Albakri et al 16 modeled FSP with in-process cooling from the backing plate using computational fluid dynamics (CFD) technic and studied the effects of different cooling channel geometries, coolant type, and coolant flow rate on the temperature history and stress distribution. Patel et al 17 numerically modeled the cooling-assisted FSW of dissimilar Al-Cu joint and reported the temperature distribution under different cooling conditions.…”

Section: Introductionmentioning

confidence: 99%

Effects of different cooling conditions on friction stir processing of A356 alloy: Numerical modeling and experiment

Akbari

Asadi

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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In the present work, the effects of in-process cooling are investigated on the material flow, temperature distribution, axial force, wear resistance, and microstructural and mechanical properties of friction stir processed (FSPed) Al-Si aluminum alloy. The finite element method (FEM) was developed for modeling the process, based on the eulerian-lagrangian technique, and then verified by the experimental force and temperature histories. Next, the material flow and temperature distribution during the friction stir process (FSP) with in-process cooling under different conditions were considered. After that, the experimental investigations, including the optical microscopy, hardness, and wear tests, were conducted. Finally, the stir zone (SZ) shape obtained by experiments and simulation model were compared for the FSPed samples without cooling and with air cooling. The material flow achievements reveal that using a coolant affects the material flow in the pin-driven zone more significantly than in the shoulder-driven zone, leading the SZ to change from the basin shape into the V shape. The SZ shapes obtained from the experiments and the simulation model show a good agreement between the shapes of the samples FSPed without cooling and with air cooling. Moreover, experimental results showed that using in-process cooling reduces Si particles' size and thus significantly increases the hardness and wear resistance. The Si particles size is reduced from 10 μm in the base metal to 2.6 μm and 2 μm in the air-cooled and water-cooled samples. Consequently, the wear mass loss reduced almost 28% and 40%, and hardness increased almost 35% and 80% for the air-cooled and water-cooled samples compared to the processed samples without coolant.

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“…Heat generation and distribution as well as cooling during the process are highly affecting the final microstructure. Heat generating from friction stir and cooling cause intense plastic deformation (material flow) through the stirring action, which create dynamically recrystallized fine grains, break up the large particles and produce defect free homogenous microstructure [9,10].…”

Section: Introductionmentioning

confidence: 99%

Effect of Friction Stir Processing on the Microstructure and Mechanical Properties of A384 Aluminum Alloy

Abdel-Aziz

Taleb

El-Baradie

et al. 2018

KEM

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Friction stir processing (FSP) is a solid-state technique for microstructural modification. The aim of this work is to evaluate the effect of input process parameters of friction stir processing (tool rotational speed rpm, travel speed mm/min) on microstructure and mechanical properties of A384 aluminum alloy. A384 aluminum alloy was cast using conventional stir casting process. The obtained alloy was subjected to friction stir process using different input parameters (rpm, mm/min) with double pass. Water was used as cooling medium during process. The microstructures of investigated alloys were characterized by optical, SEM microscopes, EDS and Map analyzer, while mechanical properties were evaluated by using tensile test. The results indicate that; after friction stir processing, the microstructure of as-cast alloy was greatly improved. Needle-like eutectic Si and Chinese Script a-Fe were modified to fine precipitates. Meanwhile, coarse primary Si and large plate b-Fe phase were dissolved. On the other hand, mapping analysis shows homogenous distribution of different alloying elements through the matrix. The higher values of tensile properties were obtained at 1200 rpm and 80 mm/min. UTS and YS were increased by 98% and50%, respectively. Meanwhile, ductility was approximately three times higher than that of cast alloy.

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Modelling of Friction Stir Processing with in Process Cooling Using Computational Fluid Dynamics Analysis

Cited by 10 publications

References 16 publications

Numerically modelled study of the plunge stage in friction stir spot welding using multi-tiered mesh partitions

Numerically modelled study of the plunge stage in friction stir spot welding using multi-tiered mesh partitions

Effects of different cooling conditions on friction stir processing of A356 alloy: Numerical modeling and experiment

Effect of Friction Stir Processing on the Microstructure and Mechanical Properties of A384 Aluminum Alloy

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