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Optimization of friction stir welding tool advance speed via Monte-Carlo simulation of the friction stir welding process

Fraser Kirk A., St-Georges Lyne et Kiss Lazlo I.. (2014). Optimization of friction stir welding tool advance speed via Monte-Carlo simulation of the friction stir welding process. Materials, 7, p. 3435-3452.

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URL officielle: http://dx.doi.org/doi:10.3390/ma7053435

Résumé

Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS). A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed) is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time.

Type de document:Article publié dans une revue avec comité d'évaluation
Volume:7
Pages:p. 3435-3452
Version évaluée par les pairs:Oui
Date:2014
Sujets:Sciences naturelles et génie > Génie > Génie des matériaux et génie métallurgique
Département, module, service et unité de recherche:Départements et modules > Département des sciences appliquées > Module d'ingénierie
Mots-clés:friction stir welding, tool speed optimization, non-linear, finite difference method, soudage par friction, optimisation de la vitesse des outils, non linéaire, méthode des différences finies
Déposé le:11 sept. 2017 17:50
Dernière modification:11 sept. 2017 17:50
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