Simulation and Thermo-Mechanical Analysis of AA6063-T5 in FSW by FEM
محورهای موضوعی : Manufacturing process monitoring and controlYunus Zarei 1 , Ahmad Afsari 2 , Seyed Mohammad Reza Nazemosadat 3 , Mohammad Mohammadi 4
1 - Department of Mechanical Engineering, Faculty of Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
2 - Department of Mechanical Engineering, College of Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
3 - Department of Mechanical Engineering, Faculty of Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
4 - Department of Mechanical Engineering, Faculty of Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
کلید واژه: Simulation, Thermal -Mechanical Analysis, AA6063-T5, FSW, FEM.,
چکیده مقاله :
Temperature prediction is essential for assessing the state of stresses, strains, and material flow during friction stir welding (FSW). In this context, the thermal and mechanical behavior of the AA6063-T5 aluminum alloy was simulated in FSW. This research utilized the Finite Element Method (FEM) for thermal and mechanical simulations, employing Abaqus/Explicit software. The first simulation focused on the thermal model, implemented through coding in FORTRAN using the Schmidt-Hotel reference model, which investigates the temperature distribution of the alloy. The second simulation was mechanical in nature; it utilized the output results from the thermal simulation to examine the stresses resulting from the FSW process. The samples were made of the same material and were butt-jointed for the operation. A tool speed of 60 mm/min, a force of 4000 newtons, and a coefficient of friction of 0.4 were applied during this process. The parameters for thermal conductivity, specific heat, coefficient of expansion, and Young's modulus were defined as temperature-dependent. The results indicated that the temperature distribution diagram at a specific point along the welding path closely matched practical examples of the FSW process. The temperature distribution contours at the beginning, middle, and end of the welding path, as well as the temperature distribution across the cross-sectional surface of the weld in the middle of the piece, were consistent with the samples. Additionally, the diagram and contour of the longitudinal residual stress in the workpiece aligned well with the completed samples.
Temperature prediction is essential for assessing the state of stresses, strains, and material flow during friction stir welding (FSW). In this context, the thermal and mechanical behavior of the AA6063-T5 aluminum alloy was simulated in FSW. This research utilized the Finite Element Method (FEM) for thermal and mechanical simulations, employing Abaqus/Explicit software. The first simulation focused on the thermal model, implemented through coding in FORTRAN using the Schmidt-Hotel reference model, which investigates the temperature distribution of the alloy. The second simulation was mechanical in nature; it utilized the output results from the thermal simulation to examine the stresses resulting from the FSW process. The samples were made of the same material and were butt-jointed for the operation. A tool speed of 60 mm/min, a force of 4000 newtons, and a coefficient of friction of 0.4 were applied during this process. The parameters for thermal conductivity, specific heat, coefficient of expansion, and Young's modulus were defined as temperature-dependent. The results indicated that the temperature distribution diagram at a specific point along the welding path closely matched practical examples of the FSW process. The temperature distribution contours at the beginning, middle, and end of the welding path, as well as the temperature distribution across the cross-sectional surface of the weld in the middle of the piece, were consistent with the samples. Additionally, the diagram and contour of the longitudinal residual stress in the workpiece aligned well with the completed samples.
[1] Rabiezadeh, A. and Afsari A. 2019. Effect of nanoparticles addition on dissimilar joining of aluminum alloys by friction stir welding. Journal of Welding Science and Technology of Iran. 4(2):23-34.
[2] Afsari, A., Heidari, S. and Jafari, J. 2020. Evaluation of optimal conditions, microstructure, and mechanical properties of aluminum to copper joints welded by FSW. Journal of Modern Processes in Manufacturing and Production, 9(4):61-81. dor: 20.1001.1.27170314.2020.9.4.6.4.
[3] Li, K., Jarrar, F., Sheikh-Ahmad, J. and Ozturk, F. 2017. Using coupled Eulerian Lagrangian formulation for accurate modeling of the friction stir welding process. Procedia Engineering. 207: 574-579. doi:10.1016/j.proeng.2017.10.1023.
[4] Niazi, M., Afsari, A., Behgozin, A. and Nazemosadat, M. R. 2023. Multi-objective optimization of kinematic tool parameters in FSW of Al-7075 and Al-6061 alloys by RSM. Journal of Welding Science and Technology of Iran. 9(1): 17-29. doi: 10.47176/JWSTI.2023.02.
[5] Buchibabu, V., Reddy, G. M., Kulkarni, D. and De, A. 2016. Friction stir welding of a thick Al-Zn-Mg alloy plate. Journal of Materials Engineering and Performance. 25:1163-1171. doi:10.1007/s11665-016-1924-8.
[6] Ahmed, S., Rahman, R. A. U., Awan, A., Ahmad, S., Akram, W., Amjad, M., Rahimian Koloor and S. S. 2022. Optimization of process parameters in friction stir welding of Aluminum 5451 in marine applications. Journal of Marine Science and Engineering. 10(10):1539. doi: 10.3390/jmse10101539.
[7] Chandrashekar, A., Kumar, B. A. and Reddappa, H. N. 2015. Friction stir welding: tool material and geometry. AKGEC International Journal of Technology. 6(1): 16-20.
[8] Meilinger, A. and Török, I. 2013. The importance of friction stir welding tool. Production Processes and Systems. 6(1): 25-34.
[9] Sambasivam, S., Gupta, N., Singh, D. P., Kumar, S., Giri, J. M. and Gupta, M. 2023. A review paper of FSW on dissimilar materials using aluminum. Materials Today: Proceedings. doi: 10.1016/j.matpr.2023.03.304.
[10] Aziz, S. B., Dewan, M. W., Huggett, D. J., Wahab, M. A. and Okeil, A. M., Liao, T. W. 2018. A fully coupled thermomechanical model of friction stir welding (FSW) and numerical studies on process parameters of lightweight aluminum alloy joints. Acta Metallurgica Sinica (English Letters). 31:1-18. doi: 10.1007/s40195-017-0658-4.
[11] Dialami, N., Cervera, M. and Chiumenti, M. 2018. Effect of the tool tilt angle on the heat generation and the material flow in friction stir welding. Metals. 9(1):28. doi: 10.3390/met9010.
[12] Derazkola, H. A., Kordani, N. and Derazkola, H. A. 2021. Effects of friction stir welding tool tilt angle on properties of Al-Mg-Si alloy T-joint. CIRP Journal of Manufacturing Science and Technology. 33:264-276. doi: 10.1016/j.cirpj.2021.03.015.
[13] Meyghani, B. and Awang, M. 2022. The influence of the tool tilt angle on the heat generation and the material behavior in friction stir welding (FSW). Metals. 12(11):1837. doi: 10.21203/rs.3.rs-1984818/v1.
[14] Ghiasvand, A. and Hassanifard, S. 2018. Numerical simulation of FSW and FSSW with pinless tool of AA6061-T6 Al alloy by CEL approach. Journal of Solid and Fluid Mechanics. 8(3):65-75. doi: 10.22044/jsfm.2018.6522.2528.
[15] Chupradit, S., Bokov, D. O., Suksatan, W., Landowski, M., Fydrych, D., Abdullah, M. E. and Derazkola, H. A. 2021. Pin angle thermal effects on friction stir welding of AA5058 aluminum alloy: CFD simulation and experimental validation. Materials. 14(24):7565. doi: 10.3390/ma14247565.
[16] Ghiasvand, A., Kazemi, M., Mahdipour Jalilian, M. and Ahmadi Rashid, H. 2020. Effects of tool offset, pin offset, and alloys position on maximum temperature in dissimilar FSW of AA6061 and AA5086. International Journal of Mechanical and Materials Engineering. 15:1-14. doi: 10.1186/s40712-020-00118-y.
[17] Derazkola, H. A. and Simchi, A. 2018. Experimental and thermomechanical analysis of the effect of tool pin profile on the friction stir welding of poly (methyl methacrylate) sheets. Journal of Manufacturing Processes. 34:412-423. doi: 10.1080/13621718.2017.1364896.
[18] Shojaeefard, M. H., Akbari, M., Asadi, P. and Khalkhali, A. 2017. The effect of reinforcement type on the microstructure, mechanical properties, and wear resistance of A356 matrix composites produced by FSP. The International Journal of Advanced Manufacturing Technology. 91:1391-1407. doi: 10.1007/s00170-016-9853-0.
[19] Shojaeefard, M. H., Akbari, M., Khalkhali, A., Asadi, P. 2018. Effect of tool pin profile on distribution of reinforcement particles during friction stir processing of B4C/aluminum composites. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 232(8):637-651. doi: 10.1177/1464420716642471.
[20] Akbari, M., Rahimi Asiabaraki, H., Hassanzadeh, E. and Esfandiar, M. 2023. Simulation of dissimilar friction stir welding of AA7075 and AA5083 aluminium alloys using Coupled Eulerian–Lagrangian approach. Welding International. 37(4):174-184. doi: 10.1080/09507116.2023.2205035.
[21] Akbari, M., Asiabaraki, H. R. and Aliha, M. R. M. 2023. Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach. Engineering Research Express. 5(2):025012. doi: 10.1088/2631-8695/acca00.
[22] El-Sayed, M. M., Shash, A. Y., Abd-Rabou, M. and ElSherbiny, M. G. 2021. Welding and processing of metallic materials by using friction stir technique: A review. Journal of Advanced Joining Processes. 3:100059. doi: 10.1016/j.jajp.2021.100059.
[23] Meyghani, B. and Wu, C. 2020. Progress in thermomechanical analysis of friction stir welding. Chinese Journal of Mechanical Engineering. 33:1-33. doi: 10.1186/s10033-020-0434-7.
[24] Lemi, M., Gutema, E. and Gopal, M. 2022. Modeling and simulation of friction stir welding process for AA6061-T6 aluminum alloy using finite element method. Engineering Solid Mechanics. 10(2):139-152. doi: 10.5267/j.esm.2022.2.001.
[25] Mishin, V., Shishov, I., Kalinenko, A., Vysotskii, I., Zuiko, I., Malopheyev, S. and Kaibyshev, R. 2022. Numerical simulation of the thermo-mechanical behavior of 6061 aluminum alloy during friction-stir welding. Journal of Manufacturing and Materials Processing. 6(4):68. doi: 10.3390/jmmp6040068.
[26] Xiao, Y. and Wu, H. 2020. An explicit coupled method of FEM and meshless particle method for simulating transient heat transfer process of friction stir welding. Mathematical Problems in Engineering. 2020:1-16. doi:10.1155/2020/2574127.
[27] Akbari, M., Asadi, P. and Sadowski, T. 2023. A review on friction stir welding/processing: numerical modeling. Materials. 16(17):5890. doi: 10.3390/ma16175890.
[28] Soori, M. Asmael, M and Solyalı, D. 2021. Recent development in friction stir welding process. SAE. International Journal of Materials and Manufacturing. 14(1):63-80. doi: 10.4271/05-14-01-0006.
[29] Ji, S. D., Jin, Y. Y., Yue, Y. M., Gao, S. S., Huang, Y. X. and Wang, L. 2013. Effect of temperature on material transfer behavior at different stages of friction stir welded 7075-T6 aluminum alloy. Journal of Materials Science & Technology. 29(10):955-960. doi: 10.1016/j.jmst.2013.05.018.
[30] Schmidt, H., Hattel, J. and Wert, J. 2003. An analytical model for the heat generation in friction stir welding. Modelling and Simulation in Materials Science and Engineering. 12(1):143. doi: 10.1088/0965-0393/12/1/013.
[31] Gholami, N., Afsari, A., Nazemosadat, S. M. R. and Afsari, M. J. 2023. Simulation and dynamic-thermal analysis of ceramic disc and brake pad for optimization by finite element method. International Journal of Advanced Design & Manufacturing Technology. 16(4):9-22. doi: 10.30486/admt.2024.1980467.1402.
[32] Nazemosadat, S. M. R., Ghanbarian, D., Naderi-Boldaji, M. and Nematollahi, M. A. 2022. Structural analysis of a mounted moldboard plow using the finite element simulation method. Spanish Journal of Agricultural Research. 20(2):e0204-e0204. doi: 10.5424/sjar/2022202-18157.
[33] Ghahremani Moghadam, D., Farhang Doost, K., Rastegar, A. and Ramezani Moghaddam, M. 2015. Tool's Speed effect on hardness and residual stress in friction stir welded Al 2024-T351: Experimental method and Numerical simulation. Modares Mechanical Engineering. 15(2):61-71. doi: 20.1001.1.10275940.1394.15.2.18.6.