Three-dimensional friction stir welding using a high payload industrial robot

2010 ◽  
Vol 4 (2-3) ◽  
pp. 127-133 ◽  
Author(s):  
Michael F. Zaeh ◽  
Georg Voellner
Keyword(s):  
Friction Stir Welding ◽  
Industrial Robot ◽  
Three Dimensional ◽  
Friction Stir ◽  
High Payload

Volumetric defect analysis in friction stir welding based on three dimensional reconstructed images

2017 ◽  
Vol 29 ◽  
pp. 96-112 ◽  
Author(s):  
Chirag Parikh ◽  
Ravi Ranjan ◽  
Aaquib Reza Khan ◽  
Rahul Jain ◽  
Raju Prasad Mahto ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Three Dimensional ◽  
Defect Analysis ◽  
Friction Stir

scholarly journals Analysis of the tool plunge in friction stir welding - comparison of aluminium alloys 2024 T3 and 2024 T351

2016 ◽  
Vol 20 (1) ◽  
pp. 247-254
Author(s):  
Darko Veljic ◽  
Bojan Medjo ◽  
Marko Rakin ◽  
Zoran Radosavljevic ◽  
Nikola Bajic
Keyword(s):  
Friction Stir Welding ◽  
Plastic Strain ◽  
Heat Generation ◽  
Aluminium Alloys ◽  
Three Dimensional ◽  
Equivalent Plastic Strain ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir ◽  
Tool Pin

Temperature, plastic strain and heat generation during the plunge stage of the friction stir welding (FSW) of high-strength aluminium alloys 2024 T3 and 2024 T351 are considered in this work. The plunging of the tool into the material is done at different rotating speeds. A three-dimensional finite element (FE) model for thermomechanical simulation is developed. It is based on arbitrary Lagrangian-Eulerian formulation, and Johnson-Cook material law is used for modelling of material behaviour. From comparison of the numerical results for alloys 2024 T3 and 2024 T351, it can be seen that the former has more intensive heat generation from the plastic deformation, due to its higher strength. Friction heat generation is only slightly different for the two alloys. Therefore, temperatures in the working plate are higher in the alloy 2024 T3 for the same parameters of the plunge stage. Equivalent plastic strain is higher for 2024 T351 alloy, and the highest values are determined under the tool shoulder and around the tool pin. For the alloy 2024 T3, equivalent plastic strain is the highest in the influence zone of the tool pin.

Computational Analysis on Weld Formation Mechanism during Self-Reacting Friction Stir Welding

2020 ◽  
pp. 1-15
Author(s):  
Chenyu Zhao ◽  
Xun Liu
Keyword(s):  
Boundary Condition ◽  
Shear Stress ◽  
Friction Stir Welding ◽  
Shear Layer ◽  
Formation Mechanism ◽  
Fluid Model ◽  
Three Dimensional ◽  
Welding Process ◽  
Weld Formation ◽  
Friction Stir

Abstract Three-dimensional computational fluid dynamics models are developed to understand physical principles of self-reacting friction stir welding process. A novel approach of predicting the weld microstructure based on plastic strain distribution at cross-section behind the tool is proposed and verified with experimental results. Limitations and credibility of shear stress and velocity tool/workpiece boundary condition are evaluated from the perspective of the weld formation mechanism. The importance of the shear layer and its sticking/sliding transition state in weld formation mechanism is emphasized. From modeling perspective, shear stress boundary, which only represents a sliding condition, neglects the movement and effects of this shear layer. When shear layer is formed, due to the velocity discontinuity which could not be captured in fluid model, velocity boundary condition, which represents an averaging effect of sticking/sliding transition between tool and shear layer, is needed.

Three-Dimensional Numerical Model Considering Phase Transformation in Friction Stir Welding of Steel

2015 ◽  
Vol 46 (12) ◽  
pp. 6040-6051 ◽  
Author(s):  
Hoon-Hwe Cho ◽  
Dong-Wan Kim ◽  
Sung-Tae Hong ◽  
Yong-Ha Jeong ◽  
Keunho Lee ◽  
...  
Keyword(s):  
Phase Transformation ◽  
Friction Stir Welding ◽  
Numerical Model ◽  
Three Dimensional ◽  
Friction Stir

Mathematical Model for Multi-Component Forces and Torque Determination in Friction Stir Welding

2011 ◽  
Vol 230-232 ◽  
pp. 1255-1259
Author(s):  
T. Khairuddin Jauhari ◽  
I.P. Almanar ◽  
Hussain Zuhailawati
Keyword(s):  
Mathematical Model ◽  
Friction Stir Welding ◽  
Early Stage ◽  
Three Dimensional ◽  
Welding Process ◽  
Temperature Dependent ◽  
Metallic Material ◽  
Friction Stir ◽  
Work Material ◽  
Force Components

Major works concentrated on the energy conversion from mechanical friction work to heat; emphasized on the immediate contact surface of work material and rotating welding tool but with no in-depth analytical study to relate the loads that are transferred to the work material and the welding fixture especially at early stage of heat generation. In this work, a mathematical model is developed to predict three-dimensional force components and axial torque of the rotating tool based on contact mechanic principle in relation to Al6061 temperature-dependent material properties. The model shows the ability to be possibly adapted for different metallic material and physical properties. It suggests the exerted torque and loads calculation endured by work material involving friction and shear mechanism of two static-dynamic contacting surface; rotating rotational tool and the fixed work material, to be used as one of the option for optimization of the welding process such as to determine the ratio of slip, non-slip contact condition through comparisons of experimental and computer simulation on the Friction Stir Welding process.

Numerical Simulations of Friction Stir Welding Process and Subsequent Post Weld Cold Rolling Process

2009 ◽  
Vol 419-420 ◽  
pp. 433-436 ◽  
Author(s):  
Yu Jie Sun ◽  
Yong Zang ◽  
Qing Yu Shi
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Three Dimensional ◽  
Welding Process ◽  
Rolling Process ◽  
Mechanical Analysis ◽  
Fusion Welding ◽  
Work Piece ◽  
Friction Stir ◽  
Longitudinal Residual Stress

A sequential coupled three-dimensional thermo-mechanical analysis was conducted first to simulate friction stir welding (FSW) of aluminum alloy. In thermal analysis, the model included adaptive heat source, contact heat transfer both between work piece and clamps and between work piece and backing board etc; in the mechanical analysis, the model involved contact interaction both between work piece and clamps and between work piece and backing board, mechanical load of tool etc. The simulation results indicate that the longitudinal residual stress is unsymmetrical about weld centerline; the magnitude of longitudinal residual stress for FSW process is lower than that for fusion welding process. Based on simulated results of FSW process, a three-dimensional elastic-plastic analysis was then carried out to simulate rolling process, the simulation result show that rolling process not only causes a marked reduction in the longitudinal tensile residual but also reverse the sign of the longitudinal residual stress.

scholarly journals Numerical Studies on Temperature and Material Flow During Friction Stir Welding using Different Tool Pin Profiles

2021 ◽  
Vol 83 (1) ◽  
pp. 91-104
Author(s):  
M. D. Bindu ◽  
P. S. Tide ◽  
A. B. Bhasi
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Material Flow ◽  
Three Dimensional ◽  
Friction Stir ◽  
Specific Strength ◽  
Numerical Studies ◽  
Computational Fluid Dynamics Cfd ◽  
Tool Pin ◽  
Metal Hardness

A three dimensional computational fluid dynamics (CFD) model has been developed to study the effect of tool pin profile on the material flow and temperature development in friction stir welding (FSW) of high specific strength AA 7068 alloy. Numerical simulations were carried out using a RNG k-e turbulence model. Three tool pin profiles, viz. cylindrical, conical and straight cylindrical threaded were considered for the simulation. The temperature distribution and material flow pattern obtained from the simulation were compared for different pin profiles. Simulation results predicted Temperature distribution and material maxing was better in straight cylindrical tapered thread pin welds. Weld joints were fabricated using the straight cylindrical threaded pin with the same parametric combinations as in the simulation. Peak temperature measured in the experiment was less than that obtained by simulation. Hardness measurements taken at different weld regions has showed that about 71% of that of the base metal hardness is obtained with the threaded tool pin. The microstructure study revealed a defect free weld joint. Precipitates distributed in the microstructure indicate sufficient heat input to join the material without dissolving precipitates. The developed numerical model is helpful in optimising FSW process parameters.

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