Analysis of Tool Used For Friction Stir Spot Welding by Explicit Meshing Scheme
Analysis of Tool Used For Friction Stir Spot Welding by Explicit Meshing Scheme
Analysis of Tool Used For Friction Stir Spot Welding by Explicit Meshing Scheme
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
Abstract : FSSW is an advanced and popular solid-state material welding method, which has achieved a
different variety of popularity in service in industries and automotive. FSSW method (technique) is used for joining
similar or dissimilar materials like aluminium, titanium, magnesium and copper alloys etc. This paper presents
finite element modeling of friction stir spot welding (FSSW) process using Abaqus/Explicit as a finite element
solver. Three-dimensional coupled thermal-stress model was used to calculate thermo-mechanical response of
FSSW process. The various factors such as rotational speed, transverse speed and profile of the tool plays a very
significant role in the joining quality of material using FSSW.
The main target of this analysis is to observe the variation of tool profile and welding quality of Ti 6Al 4V alloy
as the tool speed varies. Two Ti 6Al 4V were lapped and provided with support to the bottom of the plate known
as a back anvil to constrain the motion. This is where we analyzed the material flow due to friction of heat
generation in the weld zone. Ti 6Al 4V is one of the most commonly used materials and its applications, where
low density and excellent corrosion is applied in a wide range of resistance, are necessary in industries such as
aerospace industry and biomechanical, marine, chemical industries, gas turbine, etc.
Keywords – FSSW, Adaptive meshing, Explicit
I. INTRODUCTION
FSSW is an advanced and popular solid-state material welding method, which achieves a different variety of
popularity in serve industries and automotive. FSSW methods (technique) are used for joining the similar or
dissimilar material like aluminum, titanium, magnesium and copper alloys etc [1]. The various factors such as
rotational speed, transverse speed and profile of the tool on the joining quality of PCBN. The main target of this
analysis is to observe variation of tool profile and welding quality of PCBN as the tool speed varies. Two Ti-6Al-
4V plates were lapped and provided support to the bottom of the plate known as back anvil to constrain the motion.
This is where we analyzed the material flow due to friction of heat generation in the weld zone. PCBN is one of
the most commonly used and its applications is where low density and excellent corrosion is applied in a wide
range of resistance are necessary such as aerospace industry and biomechanical, marine, chemical industries, gas
turbine, etc. FRICTION STIR SPOT WELDING (FSSW) is a solid state joining process that transforms the metal
from solid state into a plastic state and then mechanically stirs the materials together under pressure to form a
welded joint[2,3]. In this process of welding, separate spots are weld by pressing a rotating tool with high force
onto the surface of two sheets that overlap with each other. The frictional heat and high pressure laminate the
workpiece material. The tool consists of a rotating pin and a shoulder. The pin is a part of the tool that penetrates
into the material, Tip of the pin plunges into the joint area between the adjacent materials at overlap contour. The
pin of the tool is plunged into the sheet until the shoulder is in contact with the surface of the sheet. The shoulder
applies high pressure which hook-ups the element metallurgical [4]. After a short dwell time, the tool is pulled
out of the workpiece.
This paper presents on-going finite element modeling efforts of friction stir spot welding (FSSW) process using
Abaqus/Explicit as a finite element solver. Three-dimensional coupled thermal-stress model was used to calculate
thermo-mechanical response of FSSW process [5].
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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
Tool dimensions- PCBN tool having 5 mm tip diameter and 20 mm shoulder diameter is used for study.
Different types of tool tips are used like circular, taper, triangular and square.
Plate dimension- Two Ti6-Al-4V plate are used having 3 mm thick and 80 mm length of each plate
placed as shown in fig. 1
Process description-
PLUNGING - During this process, a rotating tool with a probe is plunged into the material from the top
surface for a certain period of time to generate frictional heat. At the same time, a backing plate contacts the lower
sheet from the bottom side to support the downward force.
STIRRING -In this stage for a particular duration of time frictional heat is generated between the wear
resistant welding components and work pieces. This heat, along with that generated by the mechanical mixing
process softens the materials without melting. Heated and softened material adjacent to the tool causes plastic
flow. In addition, the tool shoulder gives a strong compressive force to the material.
DRAWING OUT - After the dwell period, the tool is withdrawn from the plunged zone and drawn away
from the material, a solid-phase weld is produced between the upper and the lower sheets. The material hardens
on cooling thereby welding the two pieces together [9,10].
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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
temperature but also to a lower plunging force and torque, which is an indication of higher softening degree of
the metals as well as lower material flow stress during welding.
Temperature result of
circular tip
At 600 rpm the temperature reaches 1754 0C
which is above the melting point material,
melting point of material Ti6Al4V is 1632 0C.
The material melts at 600 rpm. The temperature
we achieve does not lie between the plastic state
range of material Ti6Al4V which means that
Temperature result of friction stir spot welding has not been done.
square tip
At 600 rpm the temperature reaches to 1793 0C
which is above the melting point material,
melting point of material Ti6Al4V is 1632 0C.
The material melts at 600rpm.The temperature
we achieve does not lie between the plastic state
range of material Ti6Al4V which means that
Temperature result of
Triangular tip friction stir spot welding has not been done.
o
The temperature reaches 894 C at 600 rpm. The
Temperature result of
conical tip
V. CONCLUSION
We perform the FSSW process on 3 mm thick Ti6Al4V plate sheets. In this, we considered the tool with
the Lagrangian model and plate Eulerian model. The model type is the Coupled Eulerian Lagrangian (CEL).Taper
tool tip is used in this experiment. We considered the tool material is PCBN which is non-deformable and non-
consumable. The rotational speed is 600 rpm, plunge velocity is 4.3mm/time and plunge depth is 4 mm. Plunge
time is 4 sec and dwell time is 1.2 sec. The plastic state range of material Ti4Al4V is 850-1100 0C where the
actual welding process is done. In the plastic state the material changes its physical appearance, the material gets
softened and ready to weld.
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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
After observation, we can conclude that circular with a taper tool gives effective welding. In addition, the taper
tool used low to high RPM (300 rpm to 2000 rpm). The finite element method has been delineated for simulation
and analysis of friction stir spot welding process which make use of effective meshing and abatement algorithm
using an ABAQUS the combination of this features allow the thermo-elasto-plastic response to be obtained which
evidently shows the extension of the thermo-mechanically affected zone and temperature profile quickly after the
operation is completed. Without the effective meshing and abatement, schemes severe element distortion during
the welding process would prevent the simulation from converging. Even though, the capability of friction stir
spot welding to weld high strength, lightweight aluminum alloys to other materials is advantageous, extending
this process into high melting temperature materials has proven challenging due to tool cost and tool wear rates.
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