Thermal simulation on friction stir welding of AA6061 aluminum alloy by computational fluid dynamics

• Published in: International journal on interactive design and manufacturing Vol. 18; no. 5; pp. 3495 - 3505
• Main Authors: Kumar, Rajiv Ranjan, Kumar, Anup, Kumar, Amit, Ansu, Alok Kumar, Goyal, Ashish, Saxena, Kuldeep K., Prakash, Chander, Prasad, J. Laxmi
• Format: Journal Article
• Language: English
• Published: Paris Springer Paris 01-07-2024; Springer Nature B.V
• Subjects: Alloys; Aluminum alloys; Aluminum base alloys; CAE) and Design; Computational fluid dynamics; Computer-Aided Engineering (CAD; Electronics and Microelectronics; Engineering; Engineering Design; Feed rate; Finite volume method; Fluid dynamics; Friction stir welding; Heat conductivity; Heat generation; Heat transfer; High strain rate; Industrial Design; Instrumentation; Laminar flow; Mechanical Engineering; Melting points; Reynolds number; Simulation; Technical Paper; Temperature; Thermal simulation; Thermodynamic properties; Thermomechanical analysis; Thermomechanical properties; Velocity; Viscosity; Welding parameters; Workpieces; Computational fluid dynamics; Aluminum alloy 6061-T6; Friction stir welding; Design of tool pin
• ISSN: 1955-2513; 1955-2505
• DOI: 10.1007/s12008-023-01311-x

The friction stir welding computational fluid dynamics (CFD) model in three dimensions (FSW) for quantitatively study to effect heat generation on the work piece material at different tool pin profile are revealed in this study. The simulated thermal parameter are studies and compare with experimental results. The FSW process is modeled the laminar flow and transient condition for various welding condition. The rotating tool geometry such as cylindrical, tapered, triangular and square are used for FSW. Analysis of the thermomechanical behavior of various pin profiles at spindle speeds of 1000 rpm and feed rates of 16–63 mm/min. The tapered tool pin profile is effective as compared to other tool pin because it generates maximum temperature and strain rate. The tapered pin profile has lower surface area and therefore gives better performance due to maximum heat generation of 695 K and high strain rate of 0.9 S
−1
as compared to other. On the other hand, modelling results for the tapered pin profile reveal an increase in temperature of around 80% of the base materials' melting point.