Evaluation of welding characteristics using three-dimensional finite element simulation and experimentation for FSW of aluminum 6061

Technical Paper


Aim of this study is to introduce numerical 3D finite element method (FEM) simulation to study characteristics of friction stir welding. A coupled experimental and numerical simulation study was carried out to study the effect of process parameters on welding characteristics for friction stir welding of aluminium 6061. As per Box–Behnken design, 15 experiments have been conducted on aluminium 6061 plates at three levels of spindle speed, tilt angle and tool pin diameter. Experimental results of tool vibration, force in X, Y and Z directions and ultimate tensile strength were collected and analyzed. Shearing of metal and metal flow patterns during the welding were analyzed and the responses were predicted using FEM simulation. Size of the shear zone around the tool pin was studied for different combinations of the parameters. The experimental results and the FEM-simulated values were found to be in good agreement. Interaction effect of the process parameters on the responses was analyzed using response surface methodology.


Friction stir welding FEM simulation Tool vibration Welding forces Shearing of metal 



This work (Major project) was funded by Science and Engineering Research Board, Department of Science and Technology, Government of India. Grant no.: SERB/F/1761/2015-16.


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Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringVignan’s Foundation for Science, Technology and ResearchGunturIndia

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