Analyzing Thermomechanical Characteristics: A Comparative Study of Stationary Shoulder FSW and Conventional FSW

Subject Areas :

Mostafa Akbari ¹ ( IUST )
Ezatollah Hassanzadeh ² ( Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran )
Yaghoub Dadgar Asl ³ ( Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran )
Milad Esfandiar ⁴ ( Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran )
Hossein Rahimi Asiabaraki ⁵ ( Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran )

Received: 2023-11-30 Accepted : 2023-12-11 Published : 2024-02-10

Keywords: FSW, SSFSW, Force, Strain, Temperature,

Abstract :

Friction Stir Welding has significantly transformed the metal joining industry, and an innovative variation known as stationary shoulder FSW has emerged. This study aimed to compare various aspects, including force, temperature, and strain, between conventional friction stir welding (CFSW) and stationary shoulder friction stir welding (SSFSW). To accomplish this, the finite element method was employed, utilizing the lagrangian technique to model the welding process. The findings revealed that in SSFSW, the highest temperature was observed in the vicinity of the rotating pin. This was attributed to the absence of a rotating shoulder in SSFSW, which played a major role in heat generation during welding. Moreover, the longitudinal forces on the tool in SSFSW were significantly higher compared to CFSW, approximately ten times greater. In the CFSW process, the affected area showing strain usually forms a basin-shaped pattern. However, in the SSFSW process, the strain distribution is confined within the range of the tool pin.

References:

[1] Afsari, A., Saharkhiz, I. and Khadem S. M. R. 2014. Non-conventional Machinery (Electrophysical Process). Publications of Islamic Azad University of Shiraz.
[2] El-Hofy, H. A. G. 2005. Advanced Machining Processes: Nontraditional and Hybrid Machining Processes. McGraw Hill Professional.
[3] Selvarajan, L., Sasikumar, R., Kumar, N.S., Kolochi, P. and Kumar, P.N. 2021. Effect of EDM parameters on material removal rate, tool wear rate and geometrical errors of aluminium material. Materials Today: Proceedings. 46: 9392-9396. doi:10.1016/j.matpr.2020.03.054.
[4] Sarapure, S. 2023. Optimization of material removal rate and surface roughness during electric discharge machining of ultra‐fine grained Al6082 using Taguchi technique. Materialwissenschaft und Werkstofftechnik. 54(2):168-179. doi:10.1002/mawe.202200074.
[5] Arunnath, A., Madhu, S. and Tufa, M. 2022. Experimental investigation and optimization of material removal rate and tool wear in the machining of aluminum-boron carbide (Al-B4C) nanocomposite using EDM process. Advances in Materials Science and Engineering. 2022: Article ID 4254024 doi:10.1155/2022/4254024.
[6] HajHosseini, M.J., Mokhtarian, A., Rahimi, M. and Masoudi, B. 2022. Investigation and optimization of the effect of input parameters on material removal rate, tool wear rate, and surface roughness in electrical discharge machining of A356 Nano-composite reinforced by alumina. Advanced Processes in Materials Engineering. 16(3): 1-12. doi:20.1001.1.24233226.1401.16.3.1.2.
[7] Kumar, R. and Singh, B. 2020. Experimental Study for MRR and TWR on Machining of Inconel 718 using ZNC EDM. Strategic System Assurance and Business Analytics. Springer, Singapore.
[8] Rahmani, A., Mokhtarian, A. and Rahimi, M. 2021. Investigation and optimization of the effect of input parameters on output parameters of electrical discharge machining of A356 nano-composite reinforced by SiC. Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering. 13(4): 5-18.
[9] Safarabadi, A., Tahmasbi, V., Sousanabadi Farahani, A. and Zolfaghari, M. 2022. Electrical discharge machining of metal matrix composite AZ91 magnesium alloy and investigation and optimization of the effect of input parameters on material removal rate and workpiece surface roughness. Iranian Journal of Manufacturing Engineering. 9(6): 59-69. doi:10.22034/IJME.2022.160942.
[10] Motevasseli, H., Afsari, A. and Khosravifard, A. 2020. Investigation of Parameters Affecting Surface Integrity and Material Removal during Electrical Discharge Machining of HARDOX-400 Steel. Journal of Modern Processes in Manufacturing and Production. 9(2): 73-84. dor:20.1001.1.27170314.2020.9.2.6.0.
[11] Jafari, E., Afsari, A. and Abedpour, S. 2020. Predicting the Influence of Electrical Discharge Machining (EDM) Parameters on the Finished Work Surface in CK45 Steel. Journal of Modern Processes in Manufacturing and Production. 9(1): 63-78. dor: 20.1001.1.27170314.2020.9.1.6.8.
[12] Aghdeab, S.H. and Salman, T.M. 2021. Effect of Input Parameters on SR and MRR for Tool Steel AISI L2 by Electric Discharge Machine (EDM). Engineering and Technology Journal. 39(6): 928-935. doi:10.30684/etj.v39i6.1849.
[13] Heidari, S., Afsari, A. and Ranaei, M.A. 2020. Increasing wear resistance of copper electrode in electrical discharge machining by using ultra-fine-grained structure. Transactions of the Indian Institute of Metals. 73: 2901-2910. doi:10.1007/s12666-020-02091-8.
[14] William F. Smith and Hashemi, J. 2006. Foundations of Materials Science and Engineering. Mcgraw-Hill Publishing.
[15] Santhosh, A.J., Tura, A.D., Jiregna, I.T., Gemechu, W.F., Ashok, N. and Ponnusamy, M. 2021. Optimization of CNC turning parameters using face centred CCD approach in RSM and ANN-genetic algorithm for AISI 4340 alloy steel. Results in Engineering. 11: 100251. doi:10.1016/j.rineng.2021.100251.
[16] Venkateswarlu, V., Tripathy, D., Rajagopal, K., Tharian, K.T. and Venkitakrishnan, P.V. 2013. Failure analysis and optimization of thermo-mechanical process parameters of titanium alloy (Ti-6Al-4V) fasteners for aerospace applications. Case Studies in Engineering Failure Analysis. 1(2): 49-60. doi:10.1016/j.csefa.2013.04.003.
[17] Saeedifar, M. and Ahmadi Najafabadi, M. 2015. Determination of fracture toughness of heat treated AISI D2 steel using Finite Element and Acoustic Emission methods. Modares Mechanical Engineering. 14(11): 1-8. doi:20.1001.1.10275940.1393.14.11.11.0.
[18] Purushottam, N. R. A. M. D., and Dange, S. 2017. An Experimental Investigation of Machining Parameters for EDM using Electrode Shape Configuration of AISI P20 Tool Steel. IJSRD - International Journal for Scientific Research & Development. 5(9): 2321-0613.
[19] Sultan, T., Kumar, A. and Gupta, R.D. 2014. Material removal rate, electrode wear rate, and surface roughness evaluation in die sinking EDM with hollow tool through response surface methodology. International Journal of Manufacturing Engineering. 2014: Article ID 259129. doi:10.1155/2014/259129.