Material selection for milling fixture of friction stir welding using simulia

Abstract

Friction stir welding is an innovative welding technique that joins two different materials without the need for consumables. The process involves a profiled probe and shoulder tool that is rotated and plunged between the two workpieces at the interface during the friction stir process. The weld zone undergoes dynamic recrystallization, resulting in a strong bond between the materials. This method offers superior bonding compared to traditional arc welding. In the context of conventional or non-traditional milling machines, friction stir welding is performed. It is necessary to use a milling fixture to attach the plates that need to be butt and lap welded, fixture can be used in underwater FSW. To ensure the workpiece is securely held in place, a fixture or holder is necessary. In this article, friction-stir welding, and a fixture with a clamping setup are constructed. The fixture is carefully designed to consider the movement of the instrument and workpiece, and it is manufactured using CatiaV6 3D experience software. The fixture is then subjected to three different types of testing using Simulia software. The materials tested include cast iron, die steel, and tool steel. After simulation analysis, the best material for friction-stir welding operations is selected.