Abstract
A three dimensional finite element model of friction stir welding was developed by using HyperWorks® codes in order to investigate the effect of process parameters on temperature distribution, strain rate and flow stress in the weld zone of aluminium alloy AA-6061 during the operation. The planning of simulation runs has been performed in accordance with the Taguchi L9 design with three factors-each three levels. The process parameters considered are tool rotation, welding speed and pin tilt angle. Regression analysis is performed in order to investigate the effect of process parameters on response parameters during friction stir welding. A mathematical relationship was also established between input and output parameters. This study indicates that rotational speed is the most significant parameter.
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