Acta Metallurgica Sinica (English Letters) ›› 2021, Vol. 34 ›› Issue (8): 1065-1078.DOI: 10.1007/s40195-021-01198-1
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Received:
2020-11-10
Revised:
2020-12-04
Accepted:
2020-12-15
Online:
2021-02-05
Published:
2021-08-10
Contact:
Hao Su
About author:
Hao Su, suh@email.sdu.edu.cnHao Su, Chuansong Wu. Numerical Simulation for the Optimization of Polygonal Pin Profiles in Friction Stir Welding of Aluminum[J]. Acta Metallurgica Sinica (English Letters), 2021, 34(8): 1065-1078.
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Fig. 2 Calculated heat generation rates of various polygonal pin profiles (shoulder diameter: 15 mm, tool rotation speed: 800 rpm, welding speed: 160 mm/min)
Fig. 3 Calculated frictional heat generation rate at the tool-workpiece interface of various polygonal pin profiles (shoulder diameter: 15 mm, tool rotation speed: 800 rpm, welding speed: 160 mm/min)
Fig. 4 Calculated peak temperature with different polygonal pin profiles and shoulder diameters (tool rotation speed: 800 rpm, welding speed: 160 mm/min)
Fig. 5 Calculated temperature distribution on three horizontal planes of various polygonal pin profiles (shoulder diameter: 15 mm, tool rotation speed: 800 rpm, welding speed: 160 mm/min)
Fig. 6 Comparison of the thermal cycles between predicted and measured results (shoulder diameter: 15 mm, tool rotation speed: 800 rpm, welding speed: 160 mm/min): a T4f, b Conical
Fig. 7 Calculated material flow on three horizontal planes around various polygonal pin profiles (shoulder diameter: 15 mm, tool rotation speed: 800 rpm, welding speed: 160 mm/min)
Fig. 8 Calculated volume of plastic deformation zone with different polygonal pin profiles and shoulder diameters (tool rotation speed: 800 rpm, welding speed: 160 mm/min)
Fig. 9 Comparison of the weld cross section between experimental and calculated results (shoulder diameter: 15 mm, tool rotation speed: 800 rpm, welding speed: 160 mm/min): a T4f, b Conical
Fig. 10 Calculated tool torque for different shoulder diameters and welding parameters (ω/v): a SD: 12 mm, 400/160, b SD: 15 mm, 600/160, c SD: 15 mm, 800/160, d SD: 18 mm, 800/160
Fig. 11 Comparison of the tool torques between measured and calculated results for various polygonal pin profiles, shoulder diameters and welding parameters
Fig. 12 Calculated parallel and vertical torque components on the side surface of polygonal pin for different shoulder diameters and welding parameters (ω/v): a SD: 12 mm, 400/160, b SD: 15 mm, 600/160, c SD: 15 mm, 800/160, d SD: 18 mm, 800/160
Fig. 13 Calculated results of the optimization function for various shoulder diameters and welding parameters (ω/v): a 400/80, b 400/160, c 600/80, d 600/160, e 800/80, f 800/160
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