Optimization of FSW clamping systems by utilizing numerical and experimental approaches
- Schulze S. ,
- Goebel G. ,
- Fuessel U. ,
- et al
- Schulze S. ,
- Goebel G. ,
- Fuessel U. and
- Beyer E.
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Description
A 3D thermomechanical model, incorporating knowledge of residual distortion and stress, was developed as a finite element tool for simulation and optimisation of clamping situations in friction stir welding (FSW) and experiments were undertaken on AA 2024 aluminium alloy specimens with steel clamping material. The system configuration consisted of a steel backing plate (thickness 20 mm) and a rectangular AA 2024-T351 sheet (thickness 2 mm). The methodology involved a heat transfer model from which the derived temperature field was used as an initial condition in the structural model. Tensile tests were undertaken to evaluate temperature-dependent mechanical properties. FSW experiments, based on the parallel kinematic machine concept known as Pentapod, were conducted at an axial force of 4.8 kN, tool rotational speed of 1600 rpm and a feed rate of 200 mm/min. After welding, the final out-of-plane distortion was determined using a 3D surface measurement system. Results obtained by varying transversal or longitudinal clamping distance are discussed.
9th International Symposium, 15-17 May 2012, Session 9A: Process II, Paper 05
Subjects
- Friction welding
- Welding
- Process
- Friction stir welding
- Process equipment
- Computation
- Aluminium and Al alloys
- Nonferrous
- Material
- 2xxx Al series
- Strength
- Mechanical properties
- Properties
- Ultimate tensile strength
- Process conditions
- Thermal properties
- Thermal conductivity
- Stress
- Residual stresses
- Defects
- Deformation
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