Numerical modeling of friction stir welding process: a literature review (original) (raw)
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Materials Science
The paper analyzes the problem of friction stir welding (FSW) technology. The mechanism of thermo-mechanical process of the FSW method has been identified and a correlation between the weld zone and its microstructure established. Presented are the basic analytical formulations for the definition of temperature fields. Analysis of influential parameters of welding FSW technology at the zone of the weld material and mechanical properties of the realized joint was performed. Influential welding parameters were defined based on tool geometry, technological parameters of processing and the axial load of tool. Specific problems with the FSW process are related to gaps (holes) left behind by a tool at the end of the process and inflexibility of welding regarding the degree of variation of material thickness. Numerical simulation of process welding FSW proceeding was carried out on the example of Aluminum Alloy (AA 2219) using the ANSYS Mechanical ADPL (Transient Thermal) software package. The defined was the temperature field in the welding process at specified time intervals.
2017
In this work, improved heat generation models are developed for straight and tapered shoulder geometries with different tool pin profiles in friction stir welding. The models are developed considering the welding process as a combination of the pure sliding and the pure sticking conditions. From the results, the amount of heat generation is directly proportional to the number of edges in the pin profiles in such a way that the heat generated in the profiles increases from the triangular pin profile to hexagonal pin profile. Also, increase in the tool rotational speed under constant weld speed increases the heat input while increase in the weld speed under constant tool rotational speed decreases the heat input and the rate of heat generation at the shoulder in a flat shoulder tool is more than that of conical/tapered shoulder tool. The predicted results show good agreements with the experimental results in literature.
Thermal modelling of friction stir welding
Scripta Materialia, 2008
Two Friction stir welding models are presented-a global thermal model using the temperature dependent heat source and a local material flow and heat generation model allowing for detailed investigation of different contact conditions. The two models are coupled into a larger local-global model. The flow model includes frictional dissipation from the contact between the workpiece and the tool as well as plastic dissipation.
2017
The present work focuses on comparing various tool profiles for heat generation and material flow capabilities in the partial stick-slip condition of FSW process. A model with different tool profiles is generated according to the required geometry. The continuity, momentum and energy equations are solved at every mesh cell, with suitable boundary conditions given to the various surfaces of the geometry. The values of the shear stress and heat fluxes at the various boundaries are entered based on the selected condition. The observations were made on, heat generation and material flow around the workpiece in the various interfacial conditions.
MODELING OF HEAT ENERGIES AND FORCES IN FRICTION STIR WELDING
IAEME PUBLICATION, 2021
Since its inception, friction stir welding, FSW has been promising easy operation and environmental stewardship through contact friction between the tool and the weld part. The Aluminum alloy 2024-T351 was used in both working pieces. Six processes in FSW may include sticking, plunging into the welding pieces, half and full sliding, full welding along the joint line for the weld to be created, and spacing when picking away the welding tool from the weld. In determining the weld quality, their values should be within a safe range during the welding process, to derive heat from friction, modifying the parameters of the process causes variation in force in the traverse and axial directions. The ability to measure forces and understand their relationship with welding parameters is essential to a successful FSW energy strategy. The analytical models presented in this study depict each welding phase as it occurs and can be applied to predict welding forces and the heat energies.
Science and Technology of Welding and Joining, 2010
An innovative methodology for the semi-analytical calculation of the total heat generated during the friction stir welding (FSW) process is proposed. The methodology includes a simple and straightforward procedure for the determination of the heat produced due to the material stirring, combines the advantages of the conventional moving heat approach with those of alternative modelling approaches, (i.e. computational fluid dynamics or arbitrary Lagrangian Eulerian), while, simultaneously, overcomes some of their main limitations. Moreover, the predicted FSW heat energy is introduced in a global three-dimensional finite element thermal model, which predicts the spatial temperature history developing in the welded parts during the process. The overall methodology is validated through experimental temperature measurements. Finally, the global thermal model results are introduced in a thermomechanical model, from which the residual stress and distortion fields are predicted. The proposed methodology can be easily modified and used in FSW applications of variable welded plate geometry, FSW tool type, joint type and process parameters.
Development of a Finite Element Model for Thermal Analysis of Friction Stir Welding (FSW)
IOP Conf. Series: Materials Science and Engineering, 2019
Almost 2 decades ago, TWI had successfully introduced the Friction Stir Welding (FSW). During FSW, temperature increases because the friction and plastic deformation which begin at the same time. There are various reports on the assumptions and hypotheses in modelling the heat generation and the deformation of the material, however a consensus about modelling of the process is still to be reached. Over the years, scholars had proposed many numerical approaches, particularly Lagrangian, Eulerian and Arbitrary-Lagrangian-Eulerian (ALE). Researchers have deemed that choosing the most suitable numerical approach is one of the most challenging phases for FSW thermal modelling. This is because using the wrong numerical model could lead to issues such as divergence problems and high mesh distributions. Such problems could escalate when the welding transverse or rotational speeds increase. Thus, in this paper, global (structural component) level analysis was conducted, defining the problem in the Lagrangian setting. Meanwhile, an apropos kinematic framework was used at the local level. This framework uses the efficient combination Eulerian and Lagrangian descriptions for various welding speeds through the use of ABAQUS® software. The results from the temperature evaluation of the welding process are detailed in the paper. The result of the comparison between the experimental and simulated model indicates that the numerical model demonstrates the prospective methodology and its ability to accurately examine the FSW processes during different welding speeds.
The Effect of Friction Coefficient in Thermal Analysis of Friction Stir Welding (FSW)
IOP Conference Series: Materials Science and Engineering
The process of Friction Stir Welding (FSW) can be deeply investigated with the help of finite element modelling. In reality, the friction coefficient would decrease, because as the temperature rises the material becomes softer and weaker. However, past studies often presumed that the friction coefficient is a constant value, a presumption which consequently led to a disparity between the reality and the simulated model. This paper investigates the effect of applying temperature dependent and constant friction coefficient values to thermal behaviour during FSW. The comparisons between different models was done, and it was shown that the achieved temperature is affected by the friction coefficient. After comparing the results of models with results from experiments, it is concluded that the model in which temperature dependent values were applied is the most realistic one.
Numerical Analysis and Performance of Friction Stir Welding: A Review
Friction Stir Welding (FSW) is a solid state joining process which is mainly characterized by the use of a non – consumable tool of electrode for the joining of two metal pieces together. In this type of welding the tool or the material used for welding metal pieces does not melt and is non consumable unlike other welding processes. During the operation of this process a large amount of heat is generated between the rotating tool and the workpiece. In order for the correct determination and analysis of the experiments performed from FSW process, it is sometimes difficult to evaluate the right outcome due to the complex geometry of the workpieces involved. Therefore numerical analysis improves this procedure and also results in accurate results as compared from other processes. This article reports the comprehensive review on the developments and advancements in the friction stir welding process, the structure and properties of the friction stir welding.