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Simulation of Metal Flow During Friction Stir Welding Based on the Model of Interactive Force Between Tool and Material

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Abstract

In this research, the three-dimensional flow of metal in friction stir welding (FSW) has been simulated based on computational fluid dynamics. Conservation equations of mass, momentum, and energy were solved in three dimensions. The interactive force was imposed as boundary conditions on the tool/material boundary in the model. The strain rate- and temperature-dependent non-Newtonian viscosity was adopted for the calculation of metal flow. The distribution of temperature, velocity, and strain rate were simulated based on the above models. The simulated temperature distribution agreed well with the experimental results. The simulation results showed that the velocity on the pin was much higher than that on the shoulder. From the comparison between the simulation results and the experiments results, contours line, corresponding to strain rate = 4 s−1, reflected reasonably well the shape of stir zone, especially at the ground portion.

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Acknowledgments

The work was financially supported by MHI, Japan under the project of “Development of numerical simulation during friction stir welding.” The research work was also supported by the National Science and Technology Major Project of the Ministry of Science and Technology of China under the Project No. 2012ZX04012-011.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Tsinghua University, Bei**g, China

    G. Q. Chen & Q. Y. Shi

  2. Takasago Research & Development Center, Mitsubishi Heavy Industry, Ltd., Takasago, Hyogo, Japan

    Y. Fujiya & T. Horie

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  1. G. Q. Chen
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Correspondence to Q. Y. Shi.

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Chen, G.Q., Shi, Q.Y., Fujiya, Y. et al. Simulation of Metal Flow During Friction Stir Welding Based on the Model of Interactive Force Between Tool and Material. J. of Materi Eng and Perform 23, 1321–1328 (2014). https://doi.org/10.1007/s11665-014-0886-y

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  • DOI: https://doi.org/10.1007/s11665-014-0886-y

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