Finite Element Analysis (FEA) on Friction Stir Welding of Aluminium Alloy, AA5083 Using Coupled Eulerian-Lagrangian Model with Time-Scaling (original) (raw)

Friction stir welding (FSW) is a unique method of welding that can produce high quality of joint. There are various process parameters that can influence the quality which includes the welding speed, rotational speed, axial force, tool design, tool tilt angle, plunge depth, pin design, material and friction coefficient. Many researches have been conducted to study the effect of varying those parameters values to the quality of the welded joint. Based on the previous researches, the thermal-related parameters are the main contributors that affect the quality of the joint. There are two main approaches to conduct a research on FSW process; experimental and numerical simulation/analysis. Numerical analysis has proven to be more advantageous compare to experimental approaches due to its ability to discretize a model into smaller element to perform mathematical analysis. It has made the study of properties especially those properties that can distribute throughout a material such thermal distribution and stress distribution become simple with less time and cost. In this study, numerical analysis on FSW process via Finite Element Analysis (FEA) method was to be conducted by using Abaqus software. The model was developed based on Coupled Eulerian-Lagrangian approaches due to large deformation occurred during the FSW process. As the whole process to run the numerical analysis was time consuming, this study had proposed the possibilities of applying time-scaling in the simulation. The process would butt joint welding on aluminum alloy, AA5083 as the workpiece with welding speed of 16 mm/min, 28 mm/min and 40 mm/min and constant rotational speed of 500 rpm. The remaining parameters where kept constant. The proposed time-scaling method had significantly shortened the time required to perform the analysis and its feasibility would be verified based on the temperature distribution along the workpiece. v ACKNOWLEDGEMENT Final Year Project (FYP) has given me an opportunity for to develop self-learning quality. Besides that, it also helps me to equip myself with the ability to conduct a research in proper way. For this project, I have been assigned to conduct a Finite Element Analysis (FEA) on the Aluminium Alloy, (AA 5083). The project has provided me with the advantages to learn and apply Abaqus for solving engineering related problems. With the extra knowledges FEA by using Abaqus, it has equipped me with some distinctive quality as an engineering student. All of the benefits cannot be achieved without the great supports to help me in conducting the project. Therefore, I would like to express my deepest gratitude to my supervisor, Dr. Rao Srinivasa Pedapati for entrusting me with the project. He also provides some guidance to conduct the project. Besides that, we also have some constructive discussions on the ways or methods to enhance the project. I am very grateful to have a very good supervisor that has helped me a lot to complete the project. Besides that, I would like to give the outmost gratitude to my parents and friends that have gave me the moral support needed to complete the project. I really appreciate the every single knowledge and contribution from them. Some of them are willing to put some efforts to understand my project in order to help me to deal with the problems. Lastly, I also want to acknowledge Universiti Teknologi PETRONAS (UTP) for providing all the required facilities to conduct my project. It has provides computer laboratories that are equipped with various software. The laboratories are also very accommodating and comfortable. The students can utilize the laboratories to enhance their learning experiences. Sincerely, Syahmi vi Table of Contents CERTIFICATION OF APPROVAL .