Author & year

Title

Source

C. Chen & R. Kovacevic (2004)

Thermomechanical

modelling

and

force J. Mechanical
218 : pp 509-519

analysis of friction stir welding by the finite Engineering Science, element method

AIM
A 3D finite element method is proposed to study the thermal history and stress distribution in the weld and subsequently, to compute mechanical forces in the longitudinal, lateral and vertical directions.

Model Description
Tool Material -AISI A2 steel Shoulder diameter -24 mm Pin Diameter -6 mm Base material - Al 6061-T6 Workpiece dimensions 200 mm 50 mm 6.4 mm

Material properties of tool and workpiece material

Heat transfer model

The rate of heat generation derived from the friction for a single element at the interface is

dq= 2 (T) p(T) dr is the rotational speed of the tool (T) is the coefficient of friction between the tool and the material p(T) is the pressure on the shoulder of the tool The rate of heat generation over the entire interface of the contact will be q=2/3 ( (T) p(T) (Ro3-ro3))
Where Ro and ro outer radii of the tool and the probe respectively

Mechanical model
Displacement is given by
U= [D]
where [D] is the displacement function matrix

In the displacement formulation, the essential boundary conditions are specified as

Uy =0

The stressstrain equation is described as

S= [M]

Finite Element Model

Tool Used ANSYS Temperature-dependent properties are used in the modelling. The element topology used is eight nodes having three degrees of freedom at each node: translations in the nodal x , y and z directions (with a total of 3537 nodes.) Symmetry is consider

Meshed model

Experimental setup

Three axis force measurement device

Results and Discussion

Study of thermal history

A comparison of the calculated and the measured temperature histories at the location 10mm to the weld centre-line and 1.6mm below the top surface of the plate V =140mm/min and = 500 r/min)

A comparison of predicted temperature distribution and measurement along the lateral direction for nodes 1.6mm below the top surface of the plate (V = 140 mm/min,

= 500 r/min and t =34 s)

Analysis of stress distribution

Predicted principal stress

distributions in the welded plate and the tool in three directions at a time of 34 s (step 20) after the start of welding: (a) x direction; (b) y

direction; (c) z direction

Parametric study of three axis force component

Analysis of effects of rotational speed on force components

Predicted mechanical force histories in three directions at various rotational speeds of the tool: (a) 344 r/min; (b) 500 r/min; (c) 757 r/min (under constant V =140 mm/min)

Analysis of effect of traverse speed on force

components

Predicted mechanical forces in three directions at various traverse speeds of the tool =500 r/min

Comparison of predicted and measured mechanical force histories in three directions

CONCLUSIONS
The stress data are subsequently used to predict the three axial force
component. Parametric studies have been carried out to determine the effect of the

rotational speed, the traverse speed on the stress distribution, and the
mechanical force. The prediction shows that the longitudinal force is strongly influenced by the

welding parameters.
It decreases with increase in the tool rotational speed and increases with increasing traverse speed. A strong fluctuation in force occurs in the

longitudinal direction.
The vertical force decreases with increase in the rotational speed and increases slightly with increase in the traverse speed

Conclusion Contd..
The lateral force has a weak link with the rotational speed and increases slightly with increase in the traverse speed

Discussion

Author & year

Title

Source

Nandan et al., (2007)

Improving reliability of heat transfer and Welding journal, 86 : materials flow calculations during friction stir pp 313-322 welding of dissimilar aluminum alloys

AIM
Friction, slip between the tool and the workpiece, heat transfer at the bottom surface, and internal heat generation were studied for their effects on model reliability Optimization of uncertain parameters Prediction of temperature fields and magnesium

concentration profiles were examined

Process Parameters

Mathematical model
The plastic flow in three-dimensional coordinate system is represented by the momentum conservation equation

U1 p

is the density is the non-Newtonian viscosity is the welding velocity is the pressure

Viscosity can be determined from flow stress and effective strain rate

The momentum conservation equations with reference to a coordinate system attached to the heat source in index form

where , Cp k Sin Sb

is the specific heat is the thermal conductivity of the workpiece/tool. interfacial heat generation rate per unit volume is the heat generation rate due to plastic deformation

Optimization of Uncertain FSW Parameters

Where, i different rotational speeds

Experiment s (locations 13 mm from weld center) done at 710, 1000, and 1400 rev/min were used to calculate the objective function, i.e., six different thermal cycles were used. Differential Evolution technique was used to optimize the uncertain parameters.

Results and Discussion

Comparison between experimental and calculated time-temperature profile at a point 13 mm away from the centerline on the advancing side. The welding velocity was 1.05 mm/s, and the rotational speed was (A)710 and (B) 1400 rev/min

Stream-lines in a horizontal plane (A) 3.66 mm and (B) 7 mm below the top surface, showing plastic flow during FSW. Material flows along the retreating side around the pin, and a stagnant zone forms in the advancing side. The welding velocity was 1.05 mm/s and the rotational speed was 710 rev/min.

Concentration profile at depths of 1, 3, and 5 mm from the top surface, across the weld centerline for AA 6061 (advancing) and AA 1200 (retreating side) weld at 710 rev/min and a weld velocity of 1.05 mm/s. A Computed; B measured

Concentration profile at depths of 1, 3, and 5 mm from the top surface, across the weld centerline for AA 1200 (advancing) and AA 6061 (retreating side) weld at 710 rev/min and a weld velocity of 1.05 mm/s. A Computed; B measured.

Summary and Conclusion

The sensitivity of four important parameters on the computed temperature fields and torque on the tool was examined. These uncertain parameters were optimized using as small volume of experimental data, shows good agreement with the experimental data. The close agreement between the experimentally measured and the calculated thermal cycles and torque values indicates that the computed shear stress at the tool-workpiece interface is accurate and the optimization of uncertain parameters provide reliable computed results.