A Coupled Thermal-Displacement Simulation Model for Friction Stir Welding of Thin Aluminium Sheets |
Author(s): |
M. Tawadros , German University in Cairo, Egypt; M. Harraz, German University in Cairo, Egypt |
Keywords: |
Simulation, FSW, Aluminium. |
Abstract |
Friction stir welding is a novel innovative solid state welding process that is mainly used nowadays to join aluminium sheets. Due to the time and economic constraints, the verification of the experimental work using appropriate simulation models has become essential to reduce the hassle of the practical approaches. Many simulation models were designed to verify different process parameters but very little of the simulation approaches were conducted on the complete process. This present work focuses on a complete coupled thermal-displacement analysis model that is simulating the whole friction stir welding process from the 'penetration' to the final 'feed step'. For the simulation process two models were designed using Abaqus-Explicit, the first simulating the 'penetration' and 'dwelling' processes only and the second simulating 'feed steps' as well. The results of the simulation models are compared and calibrated with previous experimental work that is done on friction stir butt welded 1.5 mm aluminium sheets A6061-T6. The comparison of the experimental and simulation data has shown 95% matching of the results especially for the temperature distribution and shape of deformation obtained by the friction stir welding tool during the penetration process. The designed simulation model is therefore a proven consistent tool for simulating the unpredictable process parameters of the friction stir welding for a reliable optimization process. |
Other Details |
Paper ID: IJSRDV1I10008 Published in: Volume : 1, Issue : 10 Publication Date: 01/01/2014 Page(s): 2078-2081 |
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