Skip to main content
SpringerLink
Log in

Dynamical behaviour of machine tools during friction stir welding

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Friction stir welding (FSW) is a promising joining technology that is quickly becoming the preferred joining process for a wide range of applications. Because of their high static values, the process forces occurring during FSW still are a major factor concerning the development or the choice of friction stir welding machines. However, until now, the vast majority of research projects only consider the static force components or the maximum loads that occur during a given welding operation. But, like during turning or milling, the tool does generate oscillating process forces that induce vibrations into the machine structure and should not be neglected. Thus, the key aspect of this work is the comprehensive characterization of the dynamical nature of the process forces and their effect on the machine structure. These results are then used for the development of a process force model and the design of a machine model to simulate the response to these loads. These two models are combined in one simulation environment and interact with each other to predict the process stability for a certain combination of process parameters and machine.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Thomas WM (1991) Improvements relating to friction welding. Patent EP 0615480, The Welding Institute

  2. Midling OT, Kvale JS, Dahl O (1999) Industrialisation of the Friction Stir Welding Technology in panels production for the maritime sector. In: Proceedings of the 1st international friction stir welding symposium, Thousand Oaks

  3. Kawasaki T, Makino T, Todori S, Takai H, Ezumi M, Ina Y (2000) Application of friction stir welding to the manufacturing of next generation “A-Train” type rolling stock. In: Proceedings of the 1st international friction stir welding symposium, Gothenburg

  4. Jones C, Adams G (1999) Assembly of a full-scale external tank barrel section using friction stir welding. In: Proceedings of the 1st international friction stir welding symposium, Thousand Oaks

  5. Meyer A (2006) Tailored Welded Blanks in the new Audi R8. In: Proceedings of the 6th international symposium on friction stir welding, Saint-Sauveur

  6. Eireiner D (2006) Prozessmodelle zur statischen Auslegung von Anlagen für das Friction Stir Welding. Dissertation, Technische Universitaet Muenchen

  7. Milberg J, Eireiner D, Gebhard P (2006) Empirical model for the design of friction stir welding machines. Prod Eng Res Dev 13(2):9–14

    Google Scholar 

  8. Johnson R (2001) Forces in friction stir welding of aluminium alloys. In: Proceedings of the 1st international friction stir welding symposium, Kobe

  9. Jene T (2008) Entwicklung eines Verfahrens zur prozessintegrierten Prüfung von Rührreibschweißverbindungen des Leichtbaus sowie Charakterisierung des Ermüdungsverhaltens der Fügungen. Dissertation, Technische Universitaet Kaiserslautern

  10. Reynolds AP (2008) Flow visualization and simulation in FSW. Scr Mater 58(5):338–342

    Article  MathSciNet  Google Scholar 

  11. Mishra RS (2007) Friction stir welding and processing. ASM International, Ohio

    Google Scholar 

  12. Nunes AC (2006) Metal flow in friction stir welding. In: Proceedings of materials science & technology conference and exhibition, Cincinnati

  13. Kienzle O (1952) Die Bestimmung von Kräften und Leistungen an spanenden Werkzeugen und Werkzeugmaschinen. VDI-Z 94(11):299–305

  14. Victor H (1956) Beitrag zur Kenntnis der Schnittkräfte beim Drehen. Hobeln und Bohren, Dissertation, TH Hannover

  15. Schmidt HNB, Dickerson TL, Hattel JH (2006) Material flow in butt friction stir welds in AA2024–T3. Acta Mater 54(4):1199–1209

    Article  Google Scholar 

  16. Weck M (1996) Werkzeugmaschinen Band 4: Messtechnische Untersuchung und Beurteilung. VDI-Verlag, Duesseldorf

  17. Oertli ET (2008) Strukturmechanische Berechnung und Regelungssimulation von Werkzeugmaschinen mit elektromechanischen Vorschubantrieben. Dissertation, Technische Universitaet Muenchen

  18. Zaeh MF, Oertli T, Milberg J (2004) Finite modelling of ball screw feed drive systems. Ann CIRP––Manuf Technol 53(1):289–293

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Institute for Machine Tools and Industrial Management (iwb), Technische Universitaet Muenchen, Boltzmannstraße 15, 85748, Garching, Germany

    M. F. Zaeh & P. Gebhard

Authors
  1. M. F. Zaeh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Gebhard
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. Gebhard.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Zaeh, M.F., Gebhard, P. Dynamical behaviour of machine tools during friction stir welding. Prod. Eng. Res. Devel. 4, 615–624 (2010). https://doi.org/10.1007/s11740-010-0273-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-010-0273-y

Keywords

Search

Navigation