A Novel Tool Path Strategy for Modelling Complicated Perpendicular Curved Movements

2022

Metals

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To improve the accuracy of numerical simulation of friction stir welding (FSW) process, the tool tilt angle must be considered as a significant parameter. In this study, specific considerations for mechanical boundary conditions in Eulerian domain is employed to investigate the tool tilt angle influence on the thermomechanical behavior in FSW. Aluminum 6061-T6 with a thickness of 6 mm under a rotational speed of 800 RPM, a transverse speed of 120 mm/min, and a plunging depth of 0.1 mm were employed for the simulations. Results showed an almost symmetric temperature profile predicted by the model without considering the tool tilt angle, while after incorporating the tool tilt angle, the peak temperature point is moved to the tool backside (around 400 °C), resulting in better material bonding, enhancing the weld joint quality. Without accounting for the tool tilt angle, the highest temperature of 389 °C is observed, while with the tilt angle the maximum temperature of 413 °C is achieved. The temperature variations at different points of the leading (around 360 °C) and the trailing sides (around 400 °C) of the welding tool were measured. It was observed that, after considering the tilt angle, as the tool moves, a smooth and quick increase for the temperature at the tool trailing side is achieved. This smooth and quick increasing of the temperature at the trailing side results in reducing the possibility of the formation of defects, cracks, and voids. Finally, comparisons showed that the model computational time is acceptable, and using Eulerian formulation leads to achieving a remarkable accuracy.

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Section: Introductionmentioning

confidence: 99%

“…Meta ls 2022, 12, x FOR PEER REVIEW 2 of 24 inappropriate tilt angle causes the formation of defects [9][10][11]. Hence, investigating the effect of the tilt angle on the geometry of the contact area and the material flow velocity should be considered as significant issues [12].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Tool Tilt Angle on the Heat Generation and the Material Behavior in Friction Stir Welding (FSW)

2022

Metals

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Thermal analysis of friction stir processing (FSP) using arbitrary Lagrangian‐Eulerian (ALE) and smoothed particle hydrodynamics (SPH) meshing techniques

Materialwissenschaft Werkst

2020

Friction stir processing (FSP), a derivation of friction stir welding (FSW) is a material processing method which is used to locally modify the microstructure and texture of a given material. In friction stir processing (FSP), the heat produced by the frictional force and material deformation plays a significant role in producing a good surface quality. Therefore, the thermal modeling of friction stir processing (FSP) requires accurate boundary conditions and an appropriate mesh modelling technique. In this study, the thermal behavior of friction stir processing (FSP) using the aluminum alloy 6061‐T6 for different process parameters is investigated. To solve complicated governing equations, two finite element formulations have been utilized; i. e. an arbitrary Lagrangian‐Eulerian (ALE) and a smoothed particle hydrodynamics (SPH). For the arbitrary Lagrangian‐Eulerian (ALE), a three‐dimensional (3D) fully coupled thermomechanical finite element model using a modified Coulomb friction and Johnson‐Cook material law has been used. The results show that, the temperature behavior is asymmetrical in the cross section and the peak temperature is approximately around 60 %–80 % of the melting temperature of the AA6061‐T6. Moreover, it is seen that as the rotating velocity increases, the peak temperature is also increased; and the peak temperature decreases as the transverse speed increases. Finally, a good correlation between the calculated values and the literature is found.

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Temperature Distribution Investigation During Friction Stir Welding (FSW) Using Smoothed-Particle Hydrodynamics (SPH)

Lecture Notes in Mechanical Engineering

et al. 2020