Abstract
The role of tool pin profile is crucial in friction stir welding (FSW) process, but its optimization design still requires sufficient quantitative data and a comprehensive understanding of the thermomechanical behavior around the tool. The present work gives a systematic investigation of FSW process for tool pin with three flats by using a three-dimensional computational fluid dynamics model. The thermal response, material flow behavior, and welding loads are analyzed for tool pin with various proportion of the flat feature. The feasibility of the numerical model is verified by comparing the results with measured thermal cycle, macrostructure, tool torque, and traverse force for both tool pins with and without flat feature. Based on the numerical model, a methodology is proposed for the optimization design of tool pin profile with three flats by identifying different torque components on flat area, and also considering the material flow behavior and tool wear tendency. Furthermore, the proposed methodology is utilized for optimizing tool pin profile for a wide range of process parameters, and the precision of the optimization result is also discussed. The present approach provides an explicit solution for the computer-aided optimization design and reliability assessment of the tool pin profile in FSW.
Published Version
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