Development of FSW Simulation Model-Effect of Tool Shape on Plastic Flow

Abstract

The friction stir welding (FSW) is known as non-melting joining. Numerical analysis methods for FSW also have been developed. In these models, general grid methods have traditionally been used. However, there are some problems when these methods are employed. Calculation of the advection term for both momentum and temperature needs technical attention. To analyze a few substances of different physical properties such as the phase transformation on the bonded interface or the dissimilar joining, some complex process is required. In this study, these problems are avoided by adopting particle methods for FSW simulation. Lagrange approach is mainly used, so this particle methods calculate mass transfer and surface deformation more easily than general grid methods. The effectiveness of this method is verified by plastic flow around the tool examined by particle trace. As a result, phase transformation and tool’s shape change are taken into account for the analysis of the material flow around the tool.