Numerical Simulation of Heat Flow in Friction Stud Welding of Dissimilar Metals

详细信息    查看全文

• 作者：N. Rajesh Jesudoss Hynes (1)
  P. Nagaraj (1)
  R. Palanichamy (2)
  C. A. K. Arumugham (1)
  J. Angela Jennifa Sujana (3)
  
• 关键词：Friction stud welding ; Temperature distribution ; Microstructure ; Heat flux
• 刊名：Arabian Journal for Science and Engineering
• 出版年：2014
• 出版时间：April 2014
• 年：2014
• 卷：39
• 期：4
• 页码：3217-3224
• 全文大小：
• 参考文献：1. Wallace, F.J.; et. al.: Welding Handbook 3, 7th edn. American Welding Society, Miami, pp. 240鈥?45 (1980)
  2. Ellis, C.R.G.; Nicholas, E.D.: A Quality Monitor for Friction Welding. The Welding Institute, Great Britain, pp. 14鈥?8 (1975)
  3. Kulekci, M.K.; Kaluc, E.; Sik, A.; Basturk, O.: Experimental comparison of MIG and friction stir welding processes for EN AW-6061-T6 (Al Mg Si Cu) aluminium alloy. Arab. J. Sci. Eng. 35(1B), 321鈥?30, April (2009)
  4. Cheng, C.J.: Tranisent temperature distribution during friction welding of two similar parts. Weld. J. 41(12), 542鈥?50 (1962)
  5. Cheng, C.J.: Transient temperature distribution of two dissimilar materials in tubular form. Weld. J. 42(5), 233鈥?40 (1963)
  6. Wang, K.K.; Nagappan, P.: Transient temperature distribution in inertia welding of steels. Weld. J. 49, 419鈥?26 (1970)
  7. Wang, K.K.; Lin, W.: Flywheel friction welding research. Weld. J. 53, 233鈥?42 (1974)
  8. Kleiber, M.; Sluzalec A.: Finite element analysis of heat flow in friction welding. Eng. Trans. 32, 107鈥?13 (1984)
  9. Sluzalec, A.: Thermal effects in friction welding. Int. J. Mech. Sci. 32(6), 467鈥?78 (1990)
  10. Moal, A.; Massoni, E.: Finite element simulation of the inertia welding of two similar parts. Eng. Comput. 12(6), 497鈥?12 (1995)
  11. Vairis, A.; Frost, M.: Modeling the linear friction welding of titanium block. J. Mater. Sci. Eng. A292, 8鈥?7 (2000)
  12. Fu, L.; Duan, L.Y.; Du, S.G.: Numerical simulation of inertia friction welding process by finite element method. Weld. J. 65-S鈥?0-S (2003)
  13. Sahin, M.: Simulation of friction welding using a developed computer program. J. Mater. Process. Technol. 153鈥?54, 1011鈥?018 (2004)
  14. Akbari Mousavi, S.A.A.; Rahbar Kelishami, A.: Experimental and numerical analysis of the friction welding process for the 4340 steel and mild steel combinations. Weld. J. 87, 178s鈥?86s (2008)
  15. Seli, H.; et.al.: Mechanical evaluation and thermal modelling of friction welding of mild steel and aluminium. J. Mater. Process. Technol. 210, 1209鈥?216 (2010)
  16. Miller, S.F.; Wang, H.; Shih, A.J.; Li, R.: Experimental and numerical analysis of the friction drilling process. J. Manuf. Sci. Eng. 128(3), 802鈥?10 (2006). doi:10.1115/1.2193554
  17. Mohammed, M.B.; Bennett, C.J.; Shipway, P.H.; Hyde, T.H.: Optimization of heat transfer in the finite element process modelling of inertia friction welding of SCMV and AerMet 100. WIT Trans. Eng. Sci. 68, 253鈥?65 (2010)
  18. Sahin, A.Z.; Yilbas, B.S.; Ahmed, M.; Nickel, J.: Analysis of the friction welding process in relation to the welding of copper and steel bars. J. Mater. Process. Technol. 82(1鈥?), 127鈥?36, October (1998)
  19. Sahin, A.Z.: A 3D numerical study of heat conduction in friction welding process. Math. Comput. Appl. 1(2), 111鈥?16 (1996)
  20. Rajesh Jesudoss Hynes, N.; Nagaraj, P.; Angela Jennifa Sujana, J.: Investigation on joining of aluminium and mild steel by friction stud welding. Mater. Manuf. Process. 27(12), 1409鈥?413 (2012)
  
• 作者单位：N. Rajesh Jesudoss Hynes (1)
  P. Nagaraj (1)
  R. Palanichamy (2)
  C. A. K. Arumugham (1)
  J. Angela Jennifa Sujana (3)
  
  1. Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, 626 005, Tamil Nadu, India
  2. Department of Mechanical Engineering, Sudharsan Engineering College, Sathiyamangalam, Pudukkottai District, 622501, Tamil Nadu, India
  3. Department of Information Technology, Mepco Schlenk Engineering College, Sivakasi, 626 005, Tamil Nadu, India
  

文摘

Friction stud welding is a solid-state joining technique used for welding similar and dissimilar materials with high integrity. In friction stud welding, heat is generated by the conversion of mechanical energy into thermal energy at the interface of the work pieces during rotation under pressure. This complicated metallurgical process is accompanied by frictional heat generation, plastic deformation, cooling of high-temperature metal, and solid-state phase variation. Since the thermal cycle of friction stud welding is very short, simulation becomes a vital role to study the behaviour of materials. The simulations make it possible to observe the temperature distribution and heat transfer fields that take place during the process. In the present work, a three-dimensional nonlinear Finite Element-based heat flow model is developed for friction stud welding of aluminium and mild steel combination. The numerical model is validated with a temperature history at the weld interface measured using a non-contact-type infrared thermometer. During friction stud welding, temperature, temperature distribution, temperature gradient, heat transfer rate and their variations, govern welding parameters of a welding machine. Knowledge of them helps to determine optimum parameters and ways to improve the design and manufacture of welding machines. Hence, the developed numerical model could be used as a tool to study the thermal cycles during the process and it will be very much useful for the subsequent analysis of residual stress and distortion of welded joints.