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Friction Stir Welding (FSW) Simulation using FEA Techniques-Parametric Study using Ansys APDL

Author(s):

T.Pavan Kumar , Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India; Madhu Anupoju, Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India; Ramanjaneya Reddy Munnangi, Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India; Dr.Prabhakar Reddy, CBIT,Hyderabad

Keywords:

Parametric Study, Ansys APDL

Abstract

This thesis research implemented anewthermo- mechanical model of friction stir welding process created using ANSYS APDL commands using FEA techniques. Under this thesisseveral characteristics of FSW are studied, including tool-workpiece surface interaction, heat generation due to friction during the operating conditions of the FSW process, plastic deformation and plastic heat generation due to the non-linear nature of the materials used in finite element analysis. In this project a nonlinear direct coupled-field analysis is performed, as thermal and mechanical behaviours are mutually dependent and coupled together during the FSW process. As an initial step, the thermo mechanical model developed by Zhu and Chao for friction stir welding of 304L stainless steel was modelled using ANSYS APDL. ANSYS APDL macro is created in such a way that it can be used for multiple design variants and load parameters in order to perform the FSW study for multiple design variants. The developed model was then used to conduct parametric studies to understand the effect of various input parameters like total rate of heat input, welding speed and clamping location on temperature distribution and residual stress in the work piece. With the data arrived from the simulated models, various observations are made even with minor modifications in the input parameters. In this project a transient thermos mechanical analysis is performed using coupled field elements for different tool diameters and different sizes of the base plates which needs to be welded together using FSW.In this project FSW process is studied in various stages DWELL, PLUNGE and TRAVERSE by solving the finite element model in separate load cases. To avail the plastic heat bi-linear isotropic material properties are used. The salient observations from this project are t: 1. heat input is mainly constrained by the lower bound of the temperature for making good welds; Clamping closer to the weld is better than away from the weld in terms of lowering the peak residual stresses. Moreover, the nonlinear models resulted in a realistic solution than the linear models when wide temperature range was used at the same time as the simulation process is highly non-linear so many convergence issues will be raised. In this project bonding temperature is considered at 10000 C.

Other Details

Paper ID: RTIMEP034
Published in: Conference 7 : RTIME-2k16
Publication Date: 01/05/2016
Page(s): 194-204

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