Simulating ultrasonic vibration enhanced FSW process of AA6082 using finite element method

Abstract

Several modifications have been made on friction stir welding process to overcome some certain limitations which have been reported. One of these modifications is to use ultrasonic energy as an assistance tool in FSW process. In the present paper, a mathematical model is developed to express the heat generation during ultrasonic vibration enhanced friction stir welding process (UVeFSW). A finite element model is built to perform a transient thermal heat transfer analysis using ANSYS mechanical APDL software package. The temperature contours, temperature distribution and the thermal cycles were predicted using the moving heat source technique. To validate the model, k-type thermocouples were used to measure the temperature and thermal cycles at five locations. The results showed a good agreement between the simulated and experimentally measured results.

Optimization of Ultrasonic-assisted Friction Stir Welded using Taguchi Approach

“…A vibrating tool head (sonotrode) is considering the critical component of the processor, which evaluates the maximum amplitude and output power of the device, An ultrasonic processor processed by (Hielscher ultrasonics GmbH) was utilized to obtain the required ultrasonic vibration. Ultrasonic vibration waves of amplitude from 20 μm up to 100 μm, frequency of 20 KHz, and a power of 85 Watt were employed [9]. The ultrasonic processor is attached to the head of a milling machine through a suitable attachment as shown in Figure 1.…”

“…The enhancement in the plastic material flow have been investigated [5][6][7][8]. Mabrouk et al [9] used a mathematical model to express the heat generation during ultrasonic vibration improved friction stir welding process. The moving heat source technique was applied to simulate the welding process.…”

Mechanical and Microstructural Evaluation of AA6082-T61 Joints Produced by Ultrasonic Vibration Assisted Friction Stir Welding Process

“…Since this date, the process has attracted the attention of many researchers around the world and has received considerable research effort. These efforts included establishing the theoretical approach for the process [2], optimizing the process parameters [3], and developing *Corresponding Author Email: eng_mahmoudsamir@yahoo.com (M. S. EL-Wazery) mathematical models to predict the characteristics of the joints [4]. However, the process still suffers from certain cons [5].…”