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Nonlinear vibration and super-harmonic resonance analysis of aluminum alloy friction stir welding

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Abstract

Friction stir welding of aluminum alloy offers excellent joint quality, less residual stress and deformation, and high production efficiency when compared to conventional welding techniques. It is possible to optimize the welding process and raise the quality and efficiency of the welds by researching their nonlinear dynamic properties. In this study, a nonlinear dynamic model of friction stir welding of aluminum alloy was constructed by taking into account the flow of thermoplastic materials, time-varying upsetting force, and plastic metal friction model. The nonlinear behavior of the system was described by using bifurcation diagrams, Lyapunov exponent, time domain, fast Fourier transform (FFT) spectrum, phase plot and Poincare map. Moreover, the superharmonic resonance characteristics of the system were investigated using a multi-scale methodology, and the impact of displacement delay, displacement control, speed control, and system damping on the aluminum alloy friction stir welding system's oscillation mode were examined. According to the findings, the friction stir welding system of aluminum alloy possesses complex non-linear properties with the change of stirring pin rotation speed, feed speed and support stiffness. Furthermore, by choosing the right time delay parameters and boosting the damping, the system's stability can be enhanced.

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Acknowledgements

This research is financially supported by Guangxi Science and Technology Major Program(No. AA23073019), National Natural Science Foundation of China (No. 52265004), Open Research Fund of State Key Laboratory of Precision Manufacturing for Extreme Service Performance, Central South University (No.Kfkt2023-06), Open Fund of State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology (No. DMETKF2021017), and Innovation Project of Guangxi Graduate Education (YCSW2024052), Open Fund of High-end basic component innovation station (No. KY01080030124001), Open Fund for Academician Mao Ming's Workstation(XS-JSFW-QNKXJ-202404-007), Technology Innovation Platform Project of China Aviation Engine Group Corporation (No.CXPT-2023-044), Entrepreneurship and Innovation Talent Program of Taizhou City, Jiangsu Province.

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Author notes

  1. Shuai Mo and Yanchen Zhang contributed equally to this work, they are co-first authors of the article.

Authors and Affiliations

  1. State Key Laboratory of Featured Metal Materials and Life-Cycle Safety for Composite Structures, Guangxi University, Nanning, 530004, China

    Shuai Mo, Yanchen Zhang, Yiheng Liu, Wenbin Liu & Wei Zhang

  2. School of Mechanical Engineering, Guangxi University, Nanning, 530004, China

    Shuai Mo, Yanchen Zhang, Yiheng Liu & Wenbin Liu

  3. State Key Laboratory of Precision Manufacturing for Extreme Service Performance, Central South University, Changsha, 410083, China

    Shuai Mo & Yuansheng Zhou

  4. State Key Lab of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Shuai Mo

  5. Jiangsu Wanji Transmission Technology Co., Ltd., Taizhou, 225400, China

    Shuai Mo & Jielu Zhang

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  1. Shuai Mo
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Contributions

All authors contributed to the study conception and design. M.S. is responsible for research, resource acquisition, project design, and review and editing of the manuscript. Z.Y.C. is responsible for writing the manuscript and methodology. L.Y.H. and L.W.B. are responsible for program implementation and data visualization for the research. Z.Y.S. is responsible for data analysis. Z.J.L. is responsible for exposing to the paper provides an investigation. Z.W. is responsible for supervision and guidance.

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Correspondence to Shuai Mo.

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Shuai Mo and Yanchen Zhang contributed equally to this manuscript, and Shuai Mo and Yanchen Zhang are co-first authors of the article. We declare that we have no conflicts with other people or organizations that can inappropriately influence our work.

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Mo, S., Zhang, Y., Liu, Y. et al. Nonlinear vibration and super-harmonic resonance analysis of aluminum alloy friction stir welding. Nonlinear Dyn (2024). https://doi.org/10.1007/s11071-024-09636-2

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