Friction Stir Welding
Problem Description
Two metal sheets are joined together in a solid state through the frictional energy generated by a cylindrical tool rotating at high speed while in contact with the metal sheets to be welded.
Challenge
Controlling the operating conditions of the tool in terms of:
- Rpm
- Downward force
- Translational speed of the workpiece
- Indentation within the metal piece to obtain a high quality weld line with minimal residual stresses and minimal tool wear.
Benefit of Modeling
Multiple operating scenarios may be simulated and the effects of varying operating conditions on the transient temperature variation within the work pieces may be studied. Transient temperature maps within the metal pieces directly affect residual stresses within the heat-affected zone (HAZ).
Unique FLUENT Capabilities Used
- Moving and Deforming Mesh (MDM)
- Using a customized viscosity variation and linking it with the FLUENT model via a User-Defined Function (UDF)
