A methodology is developed for the estimation of the traverse force in friction stir welding (FSW) for various pin profiles by combining the results of numerical modelling and experimental monitoring. The effect of pin profiles on the traverse force is evaluated by introducing a modified ratio of the plastic deformation zone, which is obtained by numerical modelling. The formula is validated with the experimental data in the literature and indicates that the traverse force decreases exponentially with increasing ratio of the plastic deformation zone. The proposed methodology provides a concise approach for the estimation of the traverse force for various pin profiles in FSW and can be adopted for the design and assessment of the FSW tool.
MishraRS, MaZY.Friction stir welding and processing. Mater Sci Eng Res. 2005; 50(1–2):1–78. doi: 10.1016/j.mser.2005.07.001
3.
MehtaM, ChatterjeeK, DeA.Monitoring torque and traverse force in friction stir welding from input electrical signatures of driving motors. Sci Technol Weld Join. 2013; 18(3):191–197. doi: 10.1179/1362171812Y.0000000084
4.
SuH, WuCS, PittnerA, Simultaneous measurement of tool torque, traverse force and axial force in friction stir welding. J Manuf Process. 2013; 15(4):495–500. doi: 10.1016/j.jmapro.2013.09.001
5.
TrimbleD, MonahanJ, O'DonnellGE.Force generation during friction stir welding of AA2024-T3. CIRP Ann – Manuf Technol. 2012; 61(1):9–12. doi: 10.1016/j.cirp.2012.03.024
6.
TrimbleD, O'DonnellGE, MonaghanJ.Characterisation of tool shape and rotational speed for increased speed during friction stir welding of AA2024-T3. J Manuf Process. 2015; 17:141–150. doi: 10.1016/j.jmapro.2014.08.007
7.
SchmidtH, HattelJ, WertJ.An analytical model for the heat generation in friction stir welding. Model Simul Mater Sci Eng. 2004; 12(1):143–157. doi: 10.1088/0965-0393/12/1/013
8.
MendezPF, TelloKE, LienertTJ.Scaling of coupled heat transfer and plastic deformation around the pin in friction stir welding. Acta Mater. 2010; 58(18):6012–6026. doi: 10.1016/j.actamat.2010.07.019
9.
RoyGG, NandanR, DebRoyT.Dimensionless correlation to estimate peak temperature during friction stir welding. Sci Technol Weld Join. 2006; 11(5):606–608. doi: 10.1179/174329306X122811
HeurtierP, JonesMJ, DesrayaudC, Mechanical and thermal modelling of friction stir welding. J Mater Process Technol. 2006; 171(3):348–357. doi: 10.1016/j.jmatprotec.2005.07.014
12.
JacquinD, de MeesterB, SimarA, A simple Eulerian thermomechanical modelling of friction stir welding. J Materials Process Technol. 2011; 211(1):57–65. doi: 10.1016/j.jmatprotec.2010.08.016
13.
QianJW, LiJL, XiongJT, Periodic variation of torque and its relation to interfacial sticking and slipping during friction stir welding. Sci Technol Weld Join. 2012; 17(4):338–341. doi: 10.1179/1362171812Y.0000000001
14.
XiongJT, ZhangXC, LiP, Characterisation of periodic variation in torque occurred in friction stir welding process. Sci Technol Weld Join. 2014; 19(4):350–354. doi: 10.1179/1362171814Y.0000000195
15.
SuH, WuCS, BachmannM, Numerical modelling for the effect of pin profiles on thermal and material flow characteristics in friction stir welding. Mater Des. 2015; 77:114–125. doi: 10.1016/j.matdes.2015.04.012
16.
RamanjaneyuluK, ReddyGM, RaoAV, Structure-property correlation of AA2014 friction stir welds: role of tool pin profile. J Mater Eng Perform. 2013; 22(8):2224–2240.
17.
ElangovanK, BalasubramanianV.Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Mater Sci Eng A. 2007; 459(1-2):7–18. doi: 10.1016/j.msea.2006.12.124
18.
NandanR, DebRoyT, BhadeshiaHKDH.Recent advances in friction-stir welding – process weldment structure and properties. Progress Mater Sci. 2008; 53(6):980–1023. doi: 10.1016/j.pmatsci.2008.05.001
19.
WangH, ColegrovePA, dos SantosJF.Numerical investigation of the tool contact condition during friction stir welding of aerospace aluminium alloy. Comp Mater Sci. 2013; 71:101–108. doi: 10.1016/j.commatsci.2013.01.021
20.
MehtaM, DeA, DebRoyT.Material adhesion and stresses on friction stir welding tool pins. Sci Technol Weld Join. 2014; 19(6):534–540. doi: 10.1179/1362171814Y.0000000221
