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

Abstract:

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.

• Periodical: Advanced Materials Research (Volumes 230-232)
• Pages: 1255-1259
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.230-232.1255
• Online since: May 2011
• Authors: T. Khairuddin Jauhari, I.P. Almanar, Hussain Zuhailawati
• Keywords: Force, Friction Stir Welding (FSW), Mathematical, Model, Multi-Component, Torque

References

[1] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Templesmith, and C.J. Dawes, G.B. Patent 9125978. 8, Dec (1991).

[2] Y. M. Hwang, Z. H. Kang, Y. C. Chiou, H. H. Hsu, International Journal of Machine Tools & Manufacture, 48 (2008), Pages (778-787).

[3] E.D. Nicholas, IIW Asian Pacific International Congress, Sydney, Australia. October (2000).

[4] Ø. Frigaard, Ø. Grong and O. T Midling, Metallurgical and Material Transaction A, Volume 32A, May 2001, Pages 1189-1200.

[5] Pew, J., J. Record, T.W. Nelson, 7th International Conference on Trends in Welding Research, Pine Mountain, GA, May (2005).

[6] R. Nandan, G. G. Roy, T. J. Lienert, T. Debroy, Acta Materialia, Vol 55, 2007, Pages 883-895.

DOI: 10.1016/j.actamat.2006.09.009

[7] H. Schmidt, J. Hattel and J. Wert, Modelling and Simulation in Material Science and Engineering, Vol 12, 2004, Pages 143-157.

[8] P. A. Colegrove, H. R. Shercliff and R. Zettler, Science and Technology of Welding and Joining, Vol 12, No 4, 2007, Pages 284-297.

DOI: 10.1179/174329307x197539

[9] C. Hamilton, S. Dymek and A. Sommer, International Journal of Machine Tool & Manufacture, Vol 28, 2008, Pages 1120-1130.

[10] V. Soundaranajan, S. Zekovic, R. Kovacevic, International Journal of Machine Tool & Manufacture, Vol 45, 2005, Pages 1577-1587.

[11] Valentin L. Popov, Contact Mechanics and Frictions: Physical Principal and Application, 2010, Page 145.

[12] Military Handbook: Metallic Material and Elements for Aerospace Vehicle Structure, U. S Department of Defense. Page 44-71. Pages 44-71.

[13] F. P. Incoropera and D. P. DeWitt, Fundamental of Heat and Mass Transfer – 3rd Ed, John Wiley and Sons, Singapore (1990).

[14] O. T. Midling and Ø. Grong, Acta Metallurgica et Materialia, Vol. 42, 1994, Pages 1595-1609.

DOI: 10.1016/0956-7151(94)90369-7

[15] B. Crossland, Friction Welding, Contemporary Physics, Vol. 12, No. 6, 1971, Pages 559-574.

[16] H. S. Kong and M. F Ashby, Engineering Department Report, Cambridge University, UK, (1991).