Thermal analysis of pentagonal profiled friction stir welding tool using Ansys

Abstract

In friction stir welding process heat generation in the welding zone is most common due to the friction in between the tool and the weldment. When the heat concentration in the weld zone, then the flow of heat through the tool as well as in the weldment. It is requisite to dissipate the heat in order to weld continuously and to increase the weld distance. It is up to the tool design and tool profiles. By doing the thermal simulation in the tool, the tool temperature distribution and compare the number of tools with respect to temperature and able to finalize the tool which has maximum heat dissipation. In this work, 3 tools are designed in total with a pentagon pin profile with different volumes. Which is modeled in solid works software and converted into the Ansys file, then the material properties to be selected, each tool has different materials. Then it gives the corresponding mesh size and boundary conditions such as Temperature, Convection, etc. The tool has been mesh and found out the solution for all tools. As a result, it is found that tool number 1 has a maximum heat dissipation.

Investigation of the Effect of Tool Temperature on Microstructure, Hardness, and Wear Behaviour of Aluminium 6061-T6 Alloy Welded by the Friction Stir Welding Process

“…The FSW tool has a profiled pin and is cylindrical in shape. It typically touches the component while welding [10]. Numerous investigations on the impact of friction stir welding temperature have been done.…”