Optimizing the tool pin with three flats in friction stir welding of aluminum alloy

The role of tool pin profile is crucial in friction stir welding (FSW) process, but its optimization design still requires sufficient quantitative data and a comprehensive understanding of the thermomechanical behavior around the tool. The present work gives a systematic investigation of FSW process...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2020-05, Vol.108 (3), p.721-733
Main Authors: Su, Hao, Xue, Long, Wu, Chuansong
Format: Article
Language:English
Subjects:
Aluminum
Aluminum base alloys
CAD
CAE) and Design
Computational fluid dynamics
Computer aided design
Computer-Aided Engineering (CAD
Design optimization
Engineering
Friction stir welding
Industrial and Production Engineering
Loads (forces)
Macrostructure
Mathematical models
Mechanical Engineering
Media Management
Numerical models
Optimization
Original Article
Process parameters
Reliability analysis
Thermal response
Thermomechanical properties
Three dimensional models
Tool wear
Torque
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Summary:The role of tool pin profile is crucial in friction stir welding (FSW) process, but its optimization design still requires sufficient quantitative data and a comprehensive understanding of the thermomechanical behavior around the tool. The present work gives a systematic investigation of FSW process for tool pin with three flats by using a three-dimensional computational fluid dynamics model. The thermal response, material flow behavior, and welding loads are analyzed for tool pin with various proportion of the flat feature. The feasibility of the numerical model is verified by comparing the results with measured thermal cycle, macrostructure, tool torque, and traverse force for both tool pins with and without flat feature. Based on the numerical model, a methodology is proposed for the optimization design of tool pin profile with three flats by identifying different torque components on flat area, and also considering the material flow behavior and tool wear tendency. Furthermore, the proposed methodology is utilized for optimizing tool pin profile for a wide range of process parameters, and the precision of the optimization result is also discussed. The present approach provides an explicit solution for the computer-aided optimization design and reliability assessment of the tool pin profile in FSW.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-020-05479-4