Simulation of Tool Rotation and Travelling Speed Effects on Friction Stir Welding of Ti-6Al-4V

محورهای موضوعی : Manufacturing process monitoring and control

Hamed Aghajani Derazkola ¹ (Young Researchers and Elites club, Science and Research Branch, Islamic Azad University, Tehran, Iran)

تاریخ دریافت : 1398/07/08 تاریخ پذیرش : 1398/10/03 تاریخ انتشار : 1398/02/11

کلید واژه: Friction Stir Welding, Computational Fluid Dynamic, Thermal Modeling, Ti-6Al-4V Titanium Alloy,

چکیده مقاله :

In this research, the effects of parameters include tool rotational and traverse speeds were investigated on heat generation and material flow during friction stir welding of Ti-6Al-4V alloy with computational fluid dynamics (CFD) method. Simulation results showed that with increasing of tool rotational and decreasing tool traverse speed, the more frictional heat generates which causes formation of bigger stir zone. Results indicate that the rotation of the shoulder can accelerate the material flow behavior near the top surface. The temperature field in the friction stir welding of Ti-6Al-4V alloy was anti symmetric to the welding line. Due to the results the heat generation and temperature distribution at advancing side were more than retreating side in all joint conditions. According to the results unsmooth and disarray flow patterns were formed in stir zone which caused formation of banded layer structure in advancing side. Due to results the torque decreases with an increase in the tool rotation speed due to increases in the heat generation rate and temperature, but torque is not significantly affected by the change in welding speed. The computed pressure field was higher in front of the tool compared to the trailing edge, and it is because pressure difference is required for flow occur. According to the selected parameters in this study, maximum temperature was produced in 800rpm tool speed and the computed strain rate and pressure of workpiece in this speed were 2.3 s-1, 0635 MPa, respectively.

منابع و مأخذ:

[1] Aghajani Derazkola, H., Habibnia, M. and Jamshidi Aval, H. 2015. Study on Frictional Heat Behavior and Material Flow during Friction Stir Welding of AA1100 Aluminum Alloy. Modares Mechanical Engineering. 14: 251-261.

[2] Elyasi, M., Aghajani Derazkola, H. and Hosseinzadeh, M. 2015. Effects of Friction Stir Welding Parameters on Mechanical Quality of AA1100 Aluminum Alloy to A441 AISI Steel Joint. Modares Mechanical Engineering. 15: 379-390.

[3] Aghajani Derazkola, H., Elyasi, M. and Hosseinzadeh, M. 2016. Effects of Friction Stir Welding Tool Plunge Depth on Microstructure and Texture Evolution of AA1100 to A441 AISI Joint. International Journal of Advanced Design and Manufacturing Technology. 9: 13-20.

[4] Aghajani Derazkola, H., Elyasi, M. and Hosseinzadeh, M. 2015. Formation of Defects and Intermetallic Compounds in Friction Stir Welding of AA1100 Alloy to A441 AISI Steel. Advanced Processes in Materials. 9(3): 219-233.

[5] Elyasi, M., Aghajanai Derazkola, H. and Hosseinzadeh, M. 2016. Investigations of Tool Tilt Angle on Properties Friction Stir Welding of A441 AISI to AA1100 Aluminium. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 230(7): 1234-1241.

[6] Aghajanai Derazkola, A. and Simchi, A. 2018. Effects of Alumina Nanoparticles on the Microstructure, Strength and Wear Resistance of Poly (Methyl Methacrylate)-based Nanocomposites Prepared by Friction Stir Processing. Journal of the Mechanical Behavior of Biomedical Materials. 79: 246-253.

[7] Elyasi, M., Aghajanai Derazkola, H. and Hosseinzadeh, M. 2015. Study on Joint Zone Microstructure Evolution and Hardness in Friction Stir Welding of AA1100 Aluminum Alloy to A441 AISI Steel. Modares Mechanical Engineering. 14: 97-107.

[8] Aghajani Derazkola, H., Elyasi, M. and Hosseinzadeh, M. 2014. Feasibility Study on Aluminum Alloys and A441 AISI Steel Joints by Friction Stir Welding. International Journal of Advanced Design and Manufacturing Technology. 7: 99-109.

[9] Mironov, S., Sato, S.Y. and Kokawa H. 2018. Friction-Stir Welding and Processing of Ti-6Al-4V Titanium Alloy: A Review. Journal of Materials Science and Technology. 34(1): 58-72.

[10] Smith, C., Bendzsak, G., North, T., Hinrichs, J., Noruk, J. and Heideman, R. 1999. Heat and Material Flow Modeling of the Friction Stir Welding Process. 11th International Conference on Computer Technology in Welding, Detroit, United State.

[11] North, T., Bendzsak, G. and Smith, C. 2000. Material Properties Relevant to 3-D Modeling. 2nd International Friction Stir Welding Symposium. Gothenburg, Sweden.

[12] Seidel, T. U. and Reynolds, A. P. 2003. Two-Dimensional Friction Stir Welding Process Model based on Fluid Mechanics. Science and Technology of Welding and Joining. 8: 175-183.

[13] Zhang, W., DebRoy, T., Palmer, T. A. and Elmer, J. W. 2005. Modeling of Ferrite Formation in a Duplex Stainless Steel Weld Considering Non-Uniform Starting Microstructure. Acta Materialia. 53: 4441–4453.

[14] Nandan, R., Roy, G. and DebRoy, T. 2006. Numerical Simulation of Three Dimensional Heat Transfer and Plastic Flow During Friction Stir Welding. Metallurgical and Materials Transactions A. 37: 1247–1259.

[15] Nandan, R., Roy, G., Lienert, T. and DebRoy, T. 2006. Numerical Modelling of 3D Plastic Flow and Heat Transfer During Friction Stir Welding of Stainless Steel. Science and Technology of Welding and Joining. 11: 526-537.

[16] Nassar, H. W. and Khraisheh, M. K. 2012. Simulation of Material Flow and Heat Evolution in Friction Stir Processing Incorporating Melting. Journal of Engineering Materials and Technology. 134: 61-67.

[17] Ji, S.D., Shi, Q. Y., Zhang, L. G., Zou, A. L., Gao, S. S. and Zan, L. V. 2012. Numerical Simulation of Material Flow Behavior of Friction Stir Welding Influenced by Rotational Tool Geometry. Computational Materials Science. 63: 218–226.

[18] Aghajanai Derazkola, H. and Simchi, A. 2018. Experimental and Thermomechanical Analysis of Friction Stir Welding of Poly(Methyl Methacrylate) Sheets. Science and Technology of Welding and Joining. 23(3): 209-218.

[19] Elyasi, M. and Aghajanai Derazkola, H. 2018. Experimental and Thermomechanical Study on FSW of PMMA Polymer T-joint. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-018-1847-7.

[20] Kishore, VR. Arun, J., Padmanabhan, R. and Balasubramanian, V. 2015. Parametric Studies of Dissimilar Friction Stir Welding Using Computational Fluid Dynamics. The International Journal of Advanced Manufacturing Technology. 80(1–4): 91–98.

[21] Padmanaban, R., Kishore, V. R. and Balusamy, V. 2014. Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding of Dissimilar Aluminum Alloys. Procedia Engineering. 97: 854–863.

[22] Chen, G. 2017. Computational Fluid Dynamics Modeling on Steady-State Friction Stir Welding of Aluminum Alloy 6061 to TRIP Steel. Journal of Manufacturing Science and Engineering. 139: 1–12.

[23] Aghajani Derazkola, H., Elyasi, M. and Hosseinzadeh, M. 2015. CFD Modeling of Friction Stir Welding of AA1100 Aluminum Alloy to A441 AISI Steel Butt Joint. Journal of Advanced Materials and Processing. 3(3): 47–59.

[24] Aghajani Derazkola, H., Khodabakhshi, F. and Simchi, A. 2018. Friction-Stir Lap-Joining of Aluminium-Magnesium/Poly-methyl-methacrylate Hybrid Structures: Thermo-mechanical Modelling and Experimental Feasibility Study. Science and Technology of Welding and Joining. 23(1): 35-49.

[25] Jamshidi Aval, H., Serajzadeh, S. and Kokabi, A. H. 2011. Thermo-mechanical and Microstructural Issues in Dissimilar Friction Stir Welding of AA5086-AA6061. Journal of Material Science. 46(10): 3258–3268.

[26] Davis, J. R. 1995. Nonferrous Alloys and Special-Purpose Material, Ohio: ASM Handbook.

[27] Brandes, E. A. and Brool, G. B., 2004. Smithells Metals Reference Book, 8th Edition, Oxford:Elsevier.

[28] Liechty, B. C. and Webb, B. W., 2008. Modeling the Frictional Boundary Condition in Friction Stir Welding. International Journal of Machine Tools and Manufacture. 48: 1474-1485.

[29] Pilchak, A. L., Tang, W., Sahiner, H., Reynolds, A. P. and Williams, J. C. 2011. Microstructure Evolution during Friction Stir Welding of Mill-Annealed Ti-6Al-4V. Metallurgical and Materials Transaction A. 42: 745-762.

[30] Pilchak, A. L. and Williams, J. C. 2001. Microstructure and Texture Evolution during Friction Stir Processing of Fully Lamellar Ti-6Al-4V”, Metallurgical and Materials Transaction A. 42: 773-794.

[31] Pilchak, A. L., JUHAS, M.C. and Williams, J. C. 2007. Microstructural Changes Due to Friction Stir Processing of Investment-Cast Ti-6Al-4V. Metallurgical and Materials Transaction A. 38: 401-408.

[32] Aghajani Derazkola, H. 2017. Effects of tool linear and rotational speed on material flow and heat generation of poly methyl methacrylate (PMMA) friction stir welding. Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering. 4: 687-700.

[33] Aghajani Derazkola, Kashiry Fard, R., H. and Khodabakhshi, F. 2018. Effects of processing parameters on the characteristics of dissimilar friction-stir-welded joints between AA5058 aluminum alloy and PMMA polymer. Welding in the World. 62(1): 117-130.

[34] Arbegast, W. J. 2008. A Flow-partitioned Deformation Zone Model for Defect Formation during Friction Stir Welding. Scripta Materialia. 58: 372-376.