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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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This content will become publicly available on February 6, 2026
Impact of human body shape on free convection heat transfer
Understanding the thermal comfort and safety of diverse populations within indoor settings requires a quantitative understanding of the primary heat exchange pathways between occupants and their surroundings: radiation and free convection. Thus far, however, free convective heat transfer coefficients have only been determined for the average Western adult. To this end, we investigated how variation in body shape impacts free convection heat transfer using an experimentally validated numerical model. The multiphysics model was compared against experiments conducted using the thermal manikin ANDI (Advanced Newton Dynamic Instrument) in a climate-controlled enclosure across five air-to-skin temperature differences ranging from 4.9 to 13.9°C. The difference between measured and simulated heat fluxes for the whole body, and per anatomical region, was typically <5%, occasionally reaching 15–20%, for some body regions due to physical features not modeled in the virtual ANDI model. Using the validated model, we simulated free convection around a family, or diverse group, of virtual manikins representing the 1stto 99thpercentile body mass index (BMI) and height variation in the United States adult population. Our results show that the free convection heat transfer coefficient is independent of human sex and height but decreases slightly with increased BMI. However, the variation from the average manikin in the whole body and regional free convection coefficients with BMI was small, not exceeding 8% and 16%, respectively. Furthermore, our regression coefficients and exponents can be derived from the theorical correlation for free turbulent convection from a vertical plate, which also explains the observed independence of the heat transfer coefficient from the manikins’ height. Overall, these findings demonstrate the general applicability of using an average body shape in indoor thermal audits and/or overheating risk assessments to understand thermal comfort and heat stress. The results and valid application of the model support critical insights for human health, productivity, and well-being connected to heat and cooling in buildings.
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- PAR ID:
- 10571085
- Editor(s):
- Bhowmik, Arka
- Publisher / Repository:
- PLoS One
- Date Published:
- Journal Name:
- PLOS ONE
- Volume:
- 20
- Issue:
- 2
- ISSN:
- 1932-6203
- Page Range / eLocation ID:
- e0318842
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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