Coupled Thermo-Mechanical Modelling of Friction Stir Welding

Li, Hongjun; Mackenzie, Donald

doi:10.1115/pvp2007-26267

Cited by 7 publications

(11 citation statements)

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“…This robot has the ability of eight axes' linkage and single axial independence movement. 30,31 Taking advantage of the welding technology parameters and the workpiece geometric sizes, continuous welding is carried out on a flat sheet of aluminum alloy 2024. To compare the experimental results with simulation results, a temperature sensor is installed on the outer ring of the front angular contact ball bearing to obtain real-time temperature at different welding time instants.…”

Section: Welding Experiments Resultsmentioning

confidence: 99%

Structure design and thermal analysis of a new type of friction stir weld spindle

Luo

Xiao

et al. 2017

Advances in Mechanical Engineering

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This article aims to present a new type of friction stir weld spindle system with 2 degrees of freedom. It explains the thermal-mechanical coupling mechanism between the welding tool and the workpiece, presents simulation of the heat distribution on a friction stir weld spindle under specific welding technology parameters, and provides the type selection and the reference design for temperature-sensitive components such as bearings and motor. The spindle system, which has high stiffness and excellent resistance to overload, is developed in accordance with the welding requirement for aluminum alloy products in the aeronautic and astronautic fields. The thermal-mechanical coupling model is established between the stir-pin and the workpiece. The heat generation and transfer processes are simulated, and the results of the temperature field distribution for the target position inside the spindle structure are obtained and verified by experiments. Test results show that the spindle system can meet the requirements of friction stir welding for large-scale complex surface structures. Simulation analysis has good consistency with experimental results, as proved by experimental verification. The resulting data can provide reliable reference design and type selection of temperature-sensitive components. Compared with other stir welding heads, this system has high stiffness and overload capacity, which can well meet the high-quality welding requirements of large-scale complex surface structures. Besides that, the thermal analytical method has universal applicability and can provide solutions for temperature field distribution of spindle under different workpiece materials and welding parameters. The friction stir weld spindle system is a novel design for welding large-scale complex surface structures. Its major advantages are the high stiffness and overload capacity. In addition, the heat and thermal simulation method, consisting of two stages, has provided the type-selection reference for the spindle design.

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Section: Welding Experiments Resultsmentioning

confidence: 99%

Structure design and thermal analysis of a new type of friction stir weld spindle

Luo

Xiao

et al. 2017

Advances in Mechanical Engineering

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“…The reduced characteristic element length causes a smaller global time increment and therefore increased solution time. Scaling the mass of these elements throughout the analysis can significantly decrease the computation cost, a fixed mass factor, 10,000 was chosen for the coupled FSW model (Li, 2008). This significantly increased material density had changed the original physical problem as the density is involved in both the mechanical and thermal governing equations.…”

Section: Temperaturementioning

confidence: 99%

Multi‐physics simulation of friction stir welding process

Hamilton

Mackenzie

2010

Engineering Computations

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Article information:To cite this document: Robert Hamilton, Donald MacKenzie, Hongjun Li, (2010),"Multi-physics simulation of friction stir welding process", Engineering Computations, Vol. 27 Iss: 8 pp. 967 -985 Permanent link to this document: http://dx.Access to this document was granted through an Emerald subscription provided by University of Calgary For Authors:If you would like to write for this, or any other Emerald publication, then please use our Emerald for Authors service. Information about how to choose which publication to write for and submission guidelines are available for all. Please visit www.emeraldinsight.com/authors for more information. About Emerald www.emeraldinsight.comWith over forty years' experience, Emerald Group Publishing is a leading independent publisher of global research with impact in business, society, public policy and education. In total, Emerald publishes over 275 journals and more than 130 book series, as well as an extensive range of online products and services. Emerald is both COUNTER 3 and TRANSFER compliant. The organization is a partner of the Committee on Publication Ethics (COPE) and also works with Portico and the LOCKSS initiative for digital archive preservation. AbstractPurpose -The friction stir welding (FSW) process comprises several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation. This paper aims to present an advanced finite element (FE) model encapsulating this complex behaviour and various aspects associated with the FE model such as contact modelling, material model and meshing techniques are to be discussed in detail. Design/methodology/approach -The numerical model is continuum solid mechanics-based, fully thermo-mechanically coupled and has successfully simulated the FSW process including plunging, dwelling and welding stages. Findings -The development of several field variables are quantified by the model: temperature, stress, strain. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments. Originality/value -The model is, to the best of the authors' knowledge, the most advanced simulation of FSW published in the literature.

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“…By correlating the heat input with the experimentally measured torque and considering different types of contact conditions including sliding, sticking and partial sliding/ sticking, a 3-D thermal model was analyzed by Khandkar et al [6] A detailed review on the simplified FSW thermal model can be found in Ref. [7].…”

Section: Introductionmentioning

confidence: 99%

Identifying friction stir welding process parameters through coupled numerical and experimental analysis

Zhou¹,

Pan²,

Mackenzie³

2013

International Journal of Pressure Vessels and Piping

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Friction Stir Welding (FSW) is a complex thermal-mechanical process. Numerical models have been used to calculate the thermal field, distortion and residual stress in welded components but some modeling parameters such as film coefficient and thermal radiation of the work pieces may be technically difficult and/or expensive to measure experimentally. Therefore, it is important to establish a systematic procedure to identify FSW process parameters. In this paper, a simplified finite element model for analysis of a FSW thermal progress is proposed in which two parameters, tool heat input rate and heat loss through the backing plate, are identified as parameters for optimization through application of a generic algorithm. A genetic algorithm is used to evaluate the two thermal parameters. By comparing the FEM numerical results with experimental results, the FSW process thermal parameters have been successfully identified. This automatic parameters characterization procedure could be used for the FSW process optimization

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Coupled Thermo-Mechanical Modelling of Friction Stir Welding

Cited by 7 publications

References 0 publications

Structure design and thermal analysis of a new type of friction stir weld spindle

Structure design and thermal analysis of a new type of friction stir weld spindle

Multi‐physics simulation of friction stir welding process

Identifying friction stir welding process parameters through coupled numerical and experimental analysis

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