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Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

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Abstract

Friction Stir Welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Finite Element Method (FEM) is an important tool to predict state variables of the process but numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present work, a three dimensional coupled thermo-mechanical method based on Lagrangian implicit method is proposed to study the thermal history, strain distribution and thermo-mechanical process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Workpiece is defined as rigid-visco plastic material and sticking condition between tool and work piece is defined. Adaptive re-meshing is used to tackle high mesh distortion. Effect of tool rotational and welding speed on plastic strain is studied and insight is given on asymmetric nature of FSW process. Temperature distribution on the workpiece and tool is predicted and maximum temperature is found in workpiece top surface.

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Acknowledgments

This paper is a revised and expanded version of an article entitled, “Finite Element Simulation of Temperature and Strain Distribution in Al2024 Aluminum Alloy by Friction Stir Welding” presented in ‘5th International & 26th All India Manufacturing Technology, Design and Research Conference′, held at ‘Indian Institute of Technology Guwahati’, Guwahati, India during December 12–14, 2014.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, India

    Rahul Jain & Surjya Kanta Pal

  2. Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Kharagpur, India

    Shiv Brat Singh

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  1. Rahul Jain
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  2. Surjya Kanta Pal
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Correspondence to Rahul Jain.

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Jain, R., Pal, S.K. & Singh, S.B. Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy. J. Inst. Eng. India Ser. C 98, 37–43 (2017). https://doi.org/10.1007/s40032-016-0304-3

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  • DOI: https://doi.org/10.1007/s40032-016-0304-3

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