A Numerical Study on the Effect of Tool Speeds on Temperatures and Material Flow Behaviour in Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets
Abstract
:1. Introduction
- Step 1:
- In this step, the clamping force is applied to the workpieces, and the clamping ring and the backing anvil firmly hold the workpieces. The probe and shoulder do not initiate frictional contact with the workpiece and rotate above the workpieces.
- Step 2:
- The rotating shoulder moves vertically downwards and penetrates the workpiece (plunging), and the probes advance vertically in the direction opposite the shoulder. This action initiates deformation and frictional heating. The softened material is drawn into the reservoir; see Figure 1b.
- Step 3:
- The material (plasticized) is refilled/pushed into the workpiece by switching the vertical directions of the rotating tools in this refilling step.
- Step 4:
- The shoulder and probe’s vertical and rotational motions are stopped once Step 3 is finished, and the clamping force is released.
2. Refill FSSW: Finite Element Modeling
2.1. Refill FSSW Geometry
2.2. Material Law, Materials, and Meshing
2.3. Boundary Conditions and Contact
- Plunging stage: The shoulder plunged with the specified PR, RS, and PD. The probe went in the reverse direction vertically, with a speed of 1.25 times that of the shoulder’s PR and the same RS as that of the shoulder. The softened/plasticized material was drawn inwards into the reservoir in this step.
- Refilling stage: The probe and shoulder switched their vertical movements, maintaining the axial speed of the previous step (plunging step), allowing the material to be refilled.
3. Results and Discussion
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Temperature (°C) | 20 | 160 | 200 | 400 | 500 | 580 |
Coefficient of Friction (µ) | 0.35 | 0.3 | 0.26 | 0.08 | 0.03 | 0.01 |
Maximum Temperature (°C) at T1 | Maximum Temperature (°C) at T2 | Maximum Temperature (°C) at T3 | Maximum Temperature (°C) in SZ | % of Melting Point (635 °C) | |
---|---|---|---|---|---|
Experiment | 495 | 386 | 231 | - | - |
Model M1 | 476 | 328 | 210 | 490 | 77 |
Model M2 | 483 | 361 | 225 | 500 | 78 |
Model M3 | 506 | 377 | 246 | 520 | 81 |
Model M4 | 527 | 413 | 291 | 540 | 85 |
Model M5 | 501 | 363 | 222 | 510 | 80 |
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Janga, V.S.R.; Awang, M.; Pedapati, S.R. A Numerical Study on the Effect of Tool Speeds on Temperatures and Material Flow Behaviour in Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets. Materials 2023, 16, 3108. https://doi.org/10.3390/ma16083108
Janga VSR, Awang M, Pedapati SR. A Numerical Study on the Effect of Tool Speeds on Temperatures and Material Flow Behaviour in Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets. Materials. 2023; 16(8):3108. https://doi.org/10.3390/ma16083108
Chicago/Turabian StyleJanga, Venkata Somi Reddy, Mokhtar Awang, and Srinivasa Rao Pedapati. 2023. "A Numerical Study on the Effect of Tool Speeds on Temperatures and Material Flow Behaviour in Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets" Materials 16, no. 8: 3108. https://doi.org/10.3390/ma16083108