Pengaruh Double Chamfer terhadap Distribusi Suhu dan Daerah Zpl pada Sambungan Las Gesek AL6061 dengan Simulasi Komputer

Abstract

Welding is one of the metal joining processes in manufacturing. CDFW (continuous drive friction welding) is a welding process to join two workpieces by applying pressure at one end of the object and rotating another one where the friction action applies at interface. The purpose of this study is to study temperature distribution on the surface of the welding area and the heat-affected zone represented by a fully plasticized zone (Zpl) and to get an insight of a friction welding process. The variables of CDFW used were double chamfer angle, upset pressure, and burn off length. The initial area of friction was equal that is at a diameter of 14 mm. The method of modeling the CDFW friction welding is via computer simulations using ANSYS 18.1 software. This research uses aluminum material type Al6061. The Taguchi method was applied in designing the simulations. In this modeling, the model with the double chamfer of 15 °, the upset pressure of 120 MPa, and the burn-off length of 9 mm has a small ZPl area of 10.256 mm2. Whilst the specimen model, with a double chamfer angle of 45 °, the upset pressure of 240 MPa, and the burn-off length of 7 mm has a large Zpl area of 56.55mm2. The area of a narrow fully plasticized area caused by small chamfer angle and an upset pressure of 240 MPa. The area of fully plasticized zone shows how much material can be integrated during the friction welding process and how much strength of the weld metal. The model with the chamfer angle of 15 º, the upset pressure of 240 MPa, and the burn-off length of 9 mm has the widest temperature distribution and the highest maximum temperature. Meanwhile, the model with the chamfer angle of 30º, the upset pressure of 120 MPa, and the burn-off length of 9 mm has the narrowest temperature distribution and the lowest maximum temperature. The smaller chamfer angle increased upset pressure and burn-off length result in the wider temperature distribution, higher maximum temperature, and smaller Zpl.

The Effect of Variation of Bar Surface Chamfer Angle on Rotary Friction Welding Connections

“…It is due to the welding process. The pressure and rotational speed cause the friction surface that has reached the melting point to overflow because it cannot withstand the pressure applied and fills the space due to the creation of different chamfer angles [7], [19][20][21][22].…”

“…Friction welding is the joining of two metals by utilizing the heat energy generated from the friction of the two materials [2][3][4][5][6][7]. One metal rotates at a certain speed, and the other is given pressure so that the two metals rub against each other, producing heat so that the splicing process occurs.…”

Pengaruh Lingkungan Las terhadap Kekuatan Impak Sambungan Las Aluminum AA1100

“…Proses pengelasan adalah proses penyambungan utama dalam proses fabrikasi struktur kendaraan [7]- [9]. Proses pengelasan aluminium memiliki banyak tantangan karena sifat dari aluminium itu sendiri [10]. Aluminium memiliki konduktivitas termal yang tinggi, titik leleh yang rendah, pembentukan oksida, kelarutan hidrogen pada saat fase cair yang tinggi, dan penyusutan solidifikasi yang tinggi [11].…”

Effect of Shielding Gas on the Properties of Stainless-Steel Sus 304l Plug Welded

“…Several industries such as the automotive industry, shipping industry and the railroad industry require a good metal joining process [1]. The best metal joining process is the welding process because joining process reaches the metal structure.Welding is an important part of industrial growth, because it plays an important role in construction sector [2]- [4]. Most modern industries always involve welding processes which are increasing every year.…”