Numerical Simulation for FSW Process at Welding Aluminium Alloy AA6082-T6

Abstract

This paper presents the numerical simulation of the Friction stir welding (FSW) process obtained by using the DEFORM 3D software package. Numerical simulations are based on experimental research, welding of aluminum alloy AA6082-T6 by FSW method, which has the thickness of 7.8 mm. The aim of this paper is to determine the reliability of numerical simulations in the FSW process, which is followed by large deformations, where influential geometric and kinematic parameters are varied. Numerical research was done on the basis of the adopted five-phase orthogonal experimental plan with a variety of factors on two levels and repetition at the central point of the plan for four times. The parameters varied in the experiment are: Welding speed v mm/min, a rotation speed of tool ω rpm, angle of pin slopes α o, a diameter of the pin d mm, diameter of the shoulder D mm. During the performing of the FSW process, forces were measured in three normal directions: Axial force Fz, longitudinal force Fx and side force Fy, as well as the temperature in the adopted measuring positions of the workpiece. The experimental results obtained in this way were compared with the numerical experiment in the same adopted measuring positions, i.e., in the paper an analysis and comparison of the obtained experimental and numerical data of the measured forces and the generated temperature field were made.