Numerical Simulation for Predicting the Temperature Distribution in Friction Stir Welding of AA7020

Abstract

Friction Stir Welding (FSW) is a solid-phase joining process that uses a non-consumable tool and finds its applications in shipbuilding, aerospace and automobile industries. Heat generation plays an important role in producing good-quality welds. To understand this, a model is created and simulated in ANSYS. AA7020 workpiece is created as per the required dimensions and meshed using tetragonal and triangular elements. At every mesh cell, the governing equations for continuity, momentum and energy are solved. Suitable boundary conditions are given to the various surfaces of the geometry. The FSW model is simulated for the sticking condition and validated with the experimental value. The validated model is further simulated for sliding, partial sticking and sticking conditions of the work-piece and observations are made for temperature distribution. The maximum temperature obtained at the partial sticking condition is found to be close to the experimental value. Higher heat generation is observed in partial sticking conditions, which is more preferred condition for the FSW process.