Parametric finite-element studies on the effect of tool shape in friction stir welding

Abstract

This version is available at https://strathprints.strath.ac.uk/27456/ Strathprints is designed to allow users to access the research output of the University of Strathclyde. Unless otherwise explicitly stated on the manuscript, Copyright © and Moral Rights for the papers on this site are retained by the individual authors and/or other copyright owners. Please check the manuscript for details of any other licences that may have been applied. You may not engage in further distribution of the material for any profitmaking activities or any commercial gain. You may freely distribute both the url (https://strathprints.strath.ac.uk/) and the content of this paper for research or private study, educational, or not-for-profit purposes without prior permission or charge.Any correspondence concerning this service should be sent to the AbstractThe success of the Friction Stir Welding (FSW) process, and the weld quality produced, depends significantly on the design of the welding tool. In this paper the effect of variation in various tool geometry parameters on FSW process outcomes, during the plunge stage, were investigated. Specifically the tool shoulder surface angle and the ratio of the shoulder radius to pin radius on tool reaction force, tool torque, heat generation, temperature distribution and size of the weld zone were investigated. The studies were carried out numerically using the finite element method. The welding process used AA2024 aluminium alloy plates with a thickness of 3 mm. It was found that, in plunge stage, the larger the pin radius the higher force and torque the tool experiences and the greater heat generated. It is also found that the shoulder angle has very little effect on energy dissipation as well as little effect on temperature distribution. Tables Table 1 Typical List of Figures

A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

“…In addition to convection and radiation heat transfer, the bottom surface of the workpiece is in contact with the backing plate and the rest of the heat is transferred into the backing plate during the FSW process. Due to the complexity of the contact heat transfer problem, it was usually simplified to convection heat transfer in many previous simulations, which obtained good agreement between the simulated temperature and the experimental data [39][40][41]. In the present analysis, the same approach was adopted.…”

Processing Parameters Influence on Wear Resistance Behaviour of Friction Stir Processed Al-TiC Composites

“…However, most of the research work on FSP of aluminium and its alloys reported in the literature ranged between the 1xxx, 2xxx, 5xxx, 6xxx, and 7xxx series of alloys; these are the same series which have proven successful in the FSW experiments. Typical FSP of aluminium and its alloys found in the literature include AA1050 [6,12,13], AA2024 [14][15][16], AA2095 [17], AA5083 [18][19][20], AA5086 [21], AA6061 [22,23], and AA7075 [24]. It is shown that FSP technology is very effective in microstructure modification of reinforced metal matrix composite materials [11].…”

Multiresponse optimization of friction stir welding by an integrated ANN-PSO approach

“…Tool geometry, workpiece material, axial force, rotational speed, and feed rate of the tool are the main parameters that may significantly affect the quality of the joints. 5,6 The relationship between these parameters and the process outputs is rather complex since there is not only a direct influence between each other, but there is also a significant interaction effect on indirect parameters such as the duration of the welding or the heat generated during the process. 7–9 As an example, either an increment in the rotational speed or a reduction in the feed rate generates an increment in the thermal power generated during the process, so greatly varying the temperature distribution in the parts.…”