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Keywords = workpiece/tool interfacial heat transfer coefficient

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12 pages, 5576 KB  
Article
Effect of Workpiece/Tool Heat Transfer and Friction Coefficients on Accuracy of Simulated Temperatures and Torques in a Friction Stir Welding Plunge
by Matthew Goodson, Ryan Melander, Michael P. Miles and Troy Munro
Materials 2024, 17(1), 198; https://doi.org/10.3390/ma17010198 - 29 Dec 2023
Cited by 3 | Viewed by 1556
Abstract
Friction stir process models are typically validated by tuning heat transfer and friction coefficients until measured temperatures in either the tool or workpiece, but rarely in both, match simulated results. A three-dimensional finite element model for a tool plunge in an AA 6061-T6 [...] Read more.
Friction stir process models are typically validated by tuning heat transfer and friction coefficients until measured temperatures in either the tool or workpiece, but rarely in both, match simulated results. A three-dimensional finite element model for a tool plunge in an AA 6061-T6 is validated for temperature predictions in both the tool and workpiece using a friction coefficient that varies with time. Peak workpiece temperatures were within 1.5% of experimental temperatures and tool temperatures were off by 80 °C. The sensitivity of the predicted temperatures with respect to the workpiece/tool heat transfer coefficient was shown to be high for the tool and low for the workpiece, while the spindle torque was slightly underpredicted in the best case. These results show that workpiece/tool interface properties must be tuned by considering predictions on both sides of the heat generation interface in order to ensure a reliable process simulation. Full article
(This article belongs to the Special Issue Research on Advanced Welding Techniques)
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