Stress state analysis of friction stir welding

Friction stir welding (FSW) is a well-known joining process applied to materials with low weldability. The FSW process is subjected to an elevated stress state; however, there is no theoretical stresses analysis for the process. In this paper, a stress analysis for FSW process is developed using the...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2022-07, Vol.121 (1-2), p.1123-1134
Main Authors: Terra, Caroline, Silveira, Jose Luis L.
Format: Article
Language:English
Subjects:
Angular speed
Axial forces
Axial stress
CAE) and Design
Coefficient of friction
Computer-Aided Engineering (CAD
Differential equations
Engineering
Friction stir welding
Industrial and Production Engineering
Mechanical Engineering
Media Management
Original Article
Plastic deformation
Stress analysis
Stress state
Yield criteria
Yield stress
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Summary:Friction stir welding (FSW) is a well-known joining process applied to materials with low weldability. The FSW process is subjected to an elevated stress state; however, there is no theoretical stresses analysis for the process. In this paper, a stress analysis for FSW process is developed using the slab method. The governing differential equations are obtained through the force equilibrium and the von Mises yield criterion and solved to determine the stress state and the maximum axial force. Several models are proposed for the normal stress components based on Coulomb and Siebel friction laws. Additionally, a division into three zones of plastic deformation is used: stick zone, drag zone, and slip zone. The effect of the temperature increase is considered and the yield stress is modeled as a function of the angular speed. Experimental axial forces are measured in order to estimate the coefficient of friction. To verify the validity of the models, a validation point and published experimental results from the literature are used. The analytical results show a good agreement with the experiments, with an average percent error of 10%. The presented models provided a useful and quick knowledge, which can be applied in the dimensioning of the FSW process.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-022-09262-5