Abstract
Computational fluid dynamic model of the friction stir welding process was established. Forces acting on the welding tool were computed according to the obtained pressure fields. The obtained transverse force on the welding tool can be validated by comparison of both experimental and numerical results in published literatures. Analytical methods for the calculation of the fatigue stresses on the welding tool were then proposed. The analytical methods were compared to the finite element model for validations. Results indicate that the frictional force on the shoulder contact surface takes the main contribution to the transverse force on the welding tool. The maximum fatigue stress on the pin is decreased with the increase of the rotating speed and increased with the increase of the transverse speed.
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