Numerical Simulation Model for FSW Employing Particle Method – Effect of Tool Angle on Fluid Motion

Abstract:

The friction stir welding (FSW) is known as non-melting joining. It used widely in the field of industry. Numerical analysis models for FSW also have been developed. In these models, the most frequently used method is a grid method (finite element method or finite difference method). However it is difficult or troublesome to calculate the advective term both for momentum and temperature employing these methods. It is also difficult to calculate the big deformation of the material's free surface. Moreover, complex process is required to analyze the dissimilar joining with respect to dealing with substance transfer. In this paper, to avoid these difficulties, particle method is adopted for FSW simulation. In particle method, advective term, substance transfer, and surface deformation are calculated automatically mainly because that Lagrangian approach is used. To verify the effectiveness of this method, fluid motion around the tool is examined by particle trace. As a result, relations between the rotating speed of the tool and area of plastic flow is evaluated.

• Periodical: Materials Science Forum (Volumes 783-786)
• Pages: 1765-1769
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.783-786.1765
• Online since: May 2014
• Authors: Fumikazu Miyasaka*, Gaku Yoshikawa, Shuhei Matsuzawa
• Keywords: FSW, Material Flow, Mesh Less, Numerical Model, Onion Ring, Particle Method

References

[1] Thomas, M. W., Nicholas, J., Needham, J. C., Murch, M. G., Templesmith, P. and Dawes, C. J. Friction stir butt welding., GB Pat. Application 9125978. 8, December 1991; US Pat. 5460317, October (1995).

[2] P. Ulysse, Three-dimensional modeling of the friction stir-welding process, International Journal of Machine Tools & Manufacture 42 (2002) 1549-1557.

DOI: 10.1016/s0890-6955(02)00114-1

[3] S Guerdoux and L Fourment, A 3D numerical simulation of different phases of friction stir welding, Modelling Simul. Mater. Sci. Eng. 17 (2009) 075001 (32pp).

DOI: 10.1088/0965-0393/17/7/075001

[4] M Song and R Kovacevic, Numerical and experimental study of the heat transfer process in friction stir welding, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 217 (1), pp.73-85.

DOI: 10.1243/095440503762502297

[5] Hosein Atharifar, Dechao Lin, and Radovan Kovacevic, Numerical and Experimental Investigations on the Loads Carried by the Tool During Friction Stir Welding, Journal of Materials Engineering and Performance., 18(4), 2009, pp.339-350.

DOI: 10.1007/s11665-008-9298-1

[6] H Schmidt and J Hattel, A local model for the thermomechanical conditions in friction stir welding, Modelling Simul. Mater. Sci. Eng. 13 (2005) 77-93.

DOI: 10.1088/0965-0393/13/1/006

[7] T. Sheppard and A. Jackson, Constitutive Equations for Use in Prediction of Flow Stress During Extrusion of Aluminum Alloys, Mater. Sci. Tech., 1979, 13(3), pp.203-209.

DOI: 10.1179/mst.1997.13.3.203