A numerical methodology for predicting tool wear in Friction Stir Welding

Hasan, Ahmed F.; Bennett, Chris; Shipway, P.H.; Cater, Stephen R.; Martin, Jonathan

doi:10.1016/j.jmatprotec.2016.11.009

Cited by 38 publications

(11 citation statements)

References 34 publications

(44 reference statements)

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“…It should be noted that, in this welding method, there is no need to use expensive consumables such as cover gases. Additionally, the process can be automated and mechanized, the work-piece distortion is low and the mechanical properties is good [21,22]. Besides, through this method the energy consumption, the impact on the environment, and the costs are decreased.…”

Section: Introductionmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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Section: Introductionmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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“…FSW is being introduced approximately around last decade [9], is a solid state welding process MATEC Web of Conferences 150, 04004 (2018) https://doi.org/10.1051/matecconf/201815004004 MUCET 2017 that normally used for welding soft materials like aluminium and magnesium alloys and in addition, to dissimilar metals that frequently facing a problem due to the hard in joining by conventional fusion techniques [10][11]. FSW reveals many advantages such as low distortion and wide chemical tolerance due to the heat input in the process is below the melting point [12].…”

Section: Weldingmentioning

confidence: 99%

“…FSW reveals many advantages such as low distortion and wide chemical tolerance due to the heat input in the process is below the melting point [12]. Besides, the mechanical strength is high due to grain refinement in the heat affected zone (HAZ), low pollutions and low costs [11,13].…”

Section: Weldingmentioning

confidence: 99%

Model Updating of Friction Stir Welding for Aluminium and Magnesium Plate Structure

Nazri

Sani

Mansor

et al. 2018

MATEC Web of Conferences

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Abstract. Friction stir welding (FSW) of aluminium and magnesium alloys face high demands in automotive and aerospace application due to its advanced and lightweight properties. FSW is an emerging solid state joining process in which the material that is being welded does not melt and recast. The main objectives of this project are to perform model updating based on finite element analysis (FEA) and experimental modal analysis (EMA) of dissimilar material of aluminium alloy AL 7075 and magnesium alloy AZ 31B. Modal properties such as natural frequencies, mode shapes are obtained and compared between FEA and EMA. The discrepancies of first five modes natural frequencies are below than 10% and the model updating have been conducted to minimize the error between two methods. This model updating are based on sensitivity analysis in order to make sure which parameters are given more influence in this structural dynamic analysis. Young's modulus and Poisson's ratio both materials are selected in the model updating process. After perform model updating, total average error of the natural frequencies of dissimilar friction stir welding plate is improved significantly.

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“…Most of works are focused primarily on the mechanism that cause wear in the friction welding process [22,24,29] and prediction tool wear with numerical methods [10]. The main problem of friction welding is tool pin wear.…”

Section: Introductionmentioning

confidence: 99%

The effect of tool wear on the quality of lap joints between 7075 t6 aluminum alloy sheet metal created with the FSW method

Burek¹,

Wydrzyński²,

Sęp³

et al. 2018

Eksploatacja i Niezawodność – Maintenance and Reliability

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The article concerns the issues of tool wear effect on the quality of a friction stir welding joint quality. The experiment used aluminum alloy 7075 T6 sheet metal, which is used primarily in the aerospace industry. 1.0mm and 0.8mm thick lap joints were tested. Tool wear was determined based on multiple readings on a multisensory machine. The tool wear evaluation was done on the basis of a static tensile strength test and metallographic sections of the joints. The pin of the tool works in more demanding conditions and is more exposed to friction. This results from tooling operations performed at full depth dive in the jointed material. When also considering the small dimensions of the pin such as the diameter and the great forces occurring in this process, it is easy to see why this element is most susceptible to tool wear. The welding process causes the tool to undergo friction wear, which is the cause of reduced tool dive depth in the jointed material. As a result, it is paramount to constantly control the tool extension to achieve the desired quality parameters of the joint. After creating 200m of joints, a decrease in the strength of joints was observed as well as the repeatability of the results connected to a change in the stirring conditions in the material. The change in joint strength and tool wear is also confirmed in the metallographic analysis, which states that the continued degradation of the tool makes it subject to a decrease in size of the characteristic sizes of the thermoplastic zone that is the main determining factor of the joint strength.

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A numerical methodology for predicting tool wear in Friction Stir Welding

Cited by 38 publications

References 34 publications

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Model Updating of Friction Stir Welding for Aluminium and Magnesium Plate Structure

The effect of tool wear on the quality of lap joints between 7075 t6 aluminum alloy sheet metal created with the FSW method

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