Abstract
This work studies the effect of the tool tilt angle on the generated heat and the material flow in the work pieces joint by Friction Stir Welding (FSW). An apropos kinematic framework together with a two-stage speed-up strategy is adopted to simulate the FSW problem. The effect of tilt angle on the FSWelds is modeled through the contact condition by modifying an enhanced friction model. A rotated friction shear stress is proposed, the angle of rotation depending on the process parameters and the tilt angle. The proposed rotation angle is calibrated by the experimental data provided for a tilt angle 2.5°. The differences of generated heat and material flow for the cases of tool with tilt angle of 0° and 2.5° are discussed. It is concluded that due to the higher temperature, softer material and greater frictional force in the trailing side of the tool, the material flow in the rear side of the FSW tool with the title angle is considerably enhanced, which assists to prevent the generation of defect.
Highlights
Friction Stir Welding (FSW) uses a tool with a high rotating speed which moves forward between the pieces to be joined and generates heat
The thermo-mechanical results are presented for two tilt material flow) in FSW
The friction model is modified by introducing an in plane rotating angle β of the friction shear
Summary
Friction Stir Welding (FSW) uses a tool with a high rotating speed which moves forward between the pieces to be joined and generates heat. They study the effect of process parameters such as tilt angle to define the appropriate conditions for seeking defect-free joints They observe that the Metals 2019, 9, 28 tool tilt angle affects the material flow around the tool. It can be concluded that the tilt angle has a significant effect on the heat generation and material flow and is a controlling parameter to produce a defect free joint. We address the numerical analysis of the effect of the tool tilt angle on FSW from the computational approach developed previously by the authors [5] It allows obtaining the steady state rapidly at the speed-up phase of the simulation.
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