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  • Effect of Workpiece/Tool Heat Transfer and Friction Coefficients on Accuracy of Simulated Temperatures and Torques in a Friction Stir Welding Plunge

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Title: Effect of Workpiece/Tool Heat Transfer and Friction Coefficients on Accuracy of Simulated Temperatures and Torques in a Friction Stir Welding Plunge

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.

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Award ID(s):
1935767
NSF-PAR ID:
10483242
Author(s) / Creator(s):
; ; ;
Publisher / Repository:
MDPI
Date Published:
Journal Name:
Materials
Volume:
17
Issue:
1
ISSN:
1996-1944
Page Range / eLocation ID:
198
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
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