STUDY ON EFFECT OF TOOL GEOMETRY ON ENERGY AND TEMPERATURE OF FRICTION STIR WELDING

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1 International Journal of Civil Engineering and Technology (IJCIET) Volume 8, Issue 7, July 017, pp , Article ID: IJCIET_08_07_080 Available online at ISSN rint: and ISSN Online: IAEME ublication Scopus Indexed STUDY ON EFFECT OF TOOL GEOMETRY ON ENERGY AND TEMERATURE OF FRICTION STIR WELDING Rajiv Ranjan Kumar, Shalendra Kumar, Ashok Kumar National Institute of Technology, Jamshedpur 81014, India ABSTRACT This paper proposes a mathematical model using five different tool designs to analyze the influences of rotation speed and welding speed on the energy generation and peak temperature. Furthermore, the results obtained from mathematical modeling show that the peak temperature and energy per unit length produced during welding using cylindrical pin profile, while the triangular pin profile has the lowest temperature among all pin profile under the given working conditions. The generated energy and peak temperature models developed analytically and solved by developing a computer program in C ++ language. aper deals with reduction of time and cost of calculating the effective energy and peak temperature of the developed mathematical equations. Index Terms: C - rogramming, Tool Design, Mathematical Modeling, Heat Generation, Energy and Temperature. Cite this Article: Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar, Study on effect of Tool Geometry on Energy and Temperature of Friction Stir Welding, International Journal of Civil Engineering and Technology, 8(7), 017, pp INTRODUCTION Friction Stir Welding (FSW) is an emerging solid state welding technology first developed and patented by Wayne Thomas by The Welding Institute (TWI) of Cambridge United Kingdom in 1991 and has been a great deal of interest. This process is fast, efficient, capable of producing defect free joints, versatile and environment friendly and used in wide variety of application such as in shipbuilding, aerospace, automobile and other manufacturing industries. Initially, it has been developed for soft and light melting materials such as aluminum, by using suitable tool materials then the use of the process have been extended to harder and higher melting point materials such as steel, titanium and copper alloys, which are very difficult to weld by conventional welding. This process uses a rotating, non-consumable tool that plunges into the parent materials and moves along translational direction. The heat generated in friction stir welding process is primarily by friction between tool and work piece and the plastic deformation of the work piece material. The amount of heat generated is due to the friction and 74 editor@iaeme.com

2 Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar plastic deformation at the tool-work piece interfaces that depends on tool geometry and welding parameters. The heat generation performed at both work piece as well as the tool [1]. Absence of melting of base material in FSW, high weld quality can be fabricated which reduces solidification cracking, oxidation and other defects typical to traditional fusion welding technique []. The friction stir welding works on the principle of a rotating pin emergent from a cylindrical shoulder, which is plunged between two abutting surface and moved forward along the joint line. The materials heated by rubbing between the rotating shoulder and the work piece surface and at the same time stirred by the profiled pin leaving a solid phase bond between the two bits to be jointed. At the first stage of the welding process called plunging, the rotating tool undergoes only rotational motion at only one place until the shoulder touches the surface of the work-piece. After the work-piece become soft due to friction, the pin continuously plunged down until the pin completely positioned in the work-piece. During this stage of tool plunge, it produces lateral force orthogonal to welding or joining direction [] as shown in fig.1. Figure 1 Schematic illustration of FSW with different stages. Many authors investigated the effect of friction stir welding which has produced structural joints superior to conventional arc welds in Aluminium, Steel, Copper, Magnesium and Titanium alloys. Research and development efforts over the last two decades have resulted in improvements in friction stir welding and its related technologies. Elangovan et al. [4] investigated the effect of process parameters and mechanical properties of friction stir welded AA6061 aluminum alloy. Five different tool pin (square, cylindrical, conical, threaded cylindrical and triangular) profiles have been used to fabricate the joints at five different welding speeds. They reported that the square pin profile tool gives better results and defects free other than pin profile. Ramanjaneyulu et al. [5] considered conical, Triangular, square, entagonal and hexagonal pin profile. They found that the hexagonal tool pin profile welds have higher tensile strength, low TMAZ width, higher percentage elongation and high nugget hardness compared to other tool pin profile welds. A defect- free joint obtained when the tapered hexagonal tool pin profile used for joining aluminum alloys. Gadakh et al. [6] considered for the AA T6 aluminum alloy using tapered cylindrical and straight cylindrical pin profile. They found that the joints fabricated using the tapered pin profile a defect free weldments and fine grain structure. admanaban et al. [7] studied the selection proper tool pin profile, tool shoulder diameter and tool material to friction stir weld AZ1B magnesium alloy. Five tool pin profile, five tool materials and three tool shoulder diameters are used to fabricate the joints. They found that the joints fabricated using the threaded pin profile tool, the absence of defects; very fine equiaxed grains and higher hardness in weld region are the main reasons for superior tensile properties of these joints. Vijay et al. [8] considered for the Al editor@iaeme.com

3 Study on effect of Tool Geometry on Energy and Temperature of Friction Stir Welding %, TiB metal matrix composite material using six pin profiles such as Straight Square, straight octagon, straight hexagon, Taper Square, taper hexagon and taper octagon pin profile. The effect of pin profiles on mechanical properties are analyzed and it is found that joints welded with straight square pin profile have better mechanical properties compared to the other pin profiles. Fujii at al. [9] considered the column without threads, column with threads and triangular prism shape, pin profile used to weld three types of aluminum alloys. They reported that in the case of the 1050-H4 aluminum, a columnar tool without threads produces weld with the best mechanical properties, because this tool shape induced defects less than others did. IF steel or low carbon plain steels, a columnar tool without threads will be effective. Khodaverdizadeh et al. [10] developed a two different tool pin profile such as threaded cylindrical and square are used to fabricate the pure copper joints. They obtained results that sample welded using square pin profile has finer recrystallized grain structure and higher mechanical properties compared to sample welded by threaded cylindrical one. The square pin profile caused higher degree of plastic deformation due to its higher eccentricity and its pulsation effect. Square pin profile also resulted in higher peak temperature of the joints during FSW. Schmidt et al. [11] developed an analytical model for the heat generation for tool configuration consists of a conical shoulder and a cylindrical probe in FSW. The expression for the heat generation demonstrates a flexibility for assuming different conditions. The analytical heat generation at the tool-work-piece interface and the heat generated by the pin taking sliding/ sticking conditions into consideration. Khandkar et al. [1] considered the straight cylindrical pin profile. Experimental investigations have distributed to the different interface formed between the tool and the weld-piece based on the torques generated at different tool surface. Edwards et al. [1] proposed heat estimation model that accounts for the energy utilization during the process provides correlation between the process conditions, the process window and resulting superplastic performance of a weld. Based on the model, energy input values optimum processing are found to have energy input values between 1.4 kw and.5 kw for 5 mm thick Ti-6Al-4V sheet and tooling configuration. Ulysse et al. [14] parametric studies have conducted to determine the effect of tool speeds on welding temperatures and forces acting on the pin. redicted forces on the pin may be use to avoid tool fracture during the welding operation. Numerical models such as the one presented here will be useful in designing welding tools, which will yield desired thermal gradients and avoid tool breakage. Suresha et al. [15] It has been observed that in both the tool profiles, the tool rotational speed exhibits more influence on tensile strength than weld traversing speed and plunge depth, and that the tool having conical profile results in better joint efficiency than the tool having square profile. Mijajlovic Miroslav [16] considered have the possible influence of the material flow on heat generation as well as numerical simulation that includes a procedure for explanation of the material flow around the welding tool. Colegrave [17] uses an advanced analytical estimation of the heat generation for tools with a threaded tool pin to estimate the heat generation. Midling [18] investigated the effect of tool shoulder material and pin tool on heat input during the FSW. Kumar et al. [19] have studied the influence of different tool pin profiles (tapered cylindrical, taper cylindrical with threaded, triangular, square, pentagonal and hexagonal) on microstructure and mechanical properties of friction stir welded copper and reported that joints made using square tool pin profile resulted in better mechanical properties compared to other tool pin profiles. However, these literature studies the combined effect of tool geometries, tool rotational speed and welding speed on heat generation of friction stir welding. This paper is concerned to develop the mathematical model on energy generation and temperature of different tool geometries such as straight cylindrical, triangular, square, pentagonal and hexagonal. Later, comparison of all tool geometries in terms of energy and peak temperature has presented editor@iaeme.com

4 Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar. MATHEMATICAL MODELLING In the present study sliding condition has been considered. Based on the phenomenon mathematical modeling of different tool geometries such as cylindrical, triangular, square, pentagonal and hexagonal have been developed. Comparison of all tool geometries of total energy and peak temperature generation has been presented. The FSW process consists of a rotating tool pin penetrating into the abutting surfaces joints positioned plates to be joined and transverse motion to the tool. The shoulder surface heats the plate surface due to tool rotation whereas the pin mixes the material from the face of the pin to the pin due to tool rotation and translation. The following assumptions are introduced in the model: The heat generated at the tool shoulder/work-piece interface is frictional heat. The tool pins are cylindrical, square, triangular, pentagonal and hexagonal. The tool shoulder and the tool pin completely inserted within the workpiece. The tilt angle of the tool has taken as zero. Also, the tool shoulder is assumed to be flat. The maximum shear stress for yielding is assumed to be τ = σ yield / where the yield stress, σ yield is based on distortion energy theory for plane stress. artial sliding condition is assumed at the surface between the tool and the workpiece. Due to friction interface conditions, the frictional shear stress τ friction has considered. No heat flow into the workpiece if the local temperature reaches the material melting temperature. Due to friction interface conditions, the frictional shear stress τfriction is considered. The shear stress estimates for a sliding condition is as τ = τfriction =µ (where = F/Area under shoulder). Figure Different pin profile used in FSW. A simple tool design with shoulder surface, probe side surface and probe tip surface assumed, which is the modified version of the analytical model given by Schmidt et al. [11]. The tapered cylindrical pin surface characterized by the taper angle α. The general equation for heat generation. d = ω. dm = ω. r. df = ω. r. τ. da (1) The surface between tool and work-piece given by position and orientation relative to rotation axis editor@iaeme.com

5 Study on effect of Tool Geometry on Energy and Temperature of Friction Stir Welding A. Analytical Heat Generation Equation for Cylindrical in rofile Heat generation from the shoulder surface π R 1 =.... = S ω r τ dθ dr π ω τ R R RT ( ) S T Heat generation from the taper probe surface () π + =.... = l R RT ω τ 0 θ π ω τ r d dz l π. ω. τ H =..( R + RT ) Cosα () Heat generation from the probe tip surface π R =.... = ω r τ d θ dr π ω τ R 0 From equations, ()-(4), co ntact co ntact T calculated as: (4) = + + T 1 π. ω. τ H ( ) ( ) T =. π. ω. τ. RT RT +. π. ω. τ. R Cosα (5) But, = R.tan T H α Hence, T becomes, (6) H probe T =. π. ωτ.. [ RT +..(. RT H.tan α) + ( RT H.tan α) ] 4 Cos α (7) The energy per unit length of the weld calculated as dividing Equation (7) by weld speed (v) as ω. µ. F H R R R H R H ( α ) ( α ) = /.. [....tan.tan ]. + 4 Cos + Energy Length S T T T ν α In the case of a cylindrical pin profile, the heat generation expression simplifies to ( R ) T = R and tilt angle α =0, then T =. π. ω. τ. ( + R. H ) (9) The energy per unit length of the weld calculated as dividing Equation (9) by weld speed (v) as ω. µ. F =.. R + R. H ( ) Energy length S ν. (10) This correlates with the results found by Schmidt et al. [11] or Khandkar et al. [1]. Frigaard et al. [0, 1] have suggested the same expression without the last term. (8) editor@iaeme.com

6 Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar B. Analytical Heat Generation Equation for Square in rofile The heat generation from the shoulder surface is calculated by subtracting the heat generated due to probe tip () from the heat generated due to the shoulder (S) where a = R. is the side of the Square pin profile. 1 π. ω. τ..... a = π ω τ (11) R = a H = H a =.... =... = 0 ω τ R H = 0 R dx dy ω τ H (1) 4 π a θ = R = 4 θ = 0 R = 0 ω. τ. R. R. dθ. dr = (1) From equations (11-1), T calculated as T = T =. π. ω. τ. +. R. H π (14) The energy per unit length of the weld calculated by dividing Equation (14) by the weld speed (v) as ω. µ. F Energy length = R H ν. π (15) C. Analytical Heat Generation Equation for Triangular in rofile Heat generation from shoulder surface is calculated by subtracting the heat generated due to probe tip () from the heat generated due to shoulder (S) where a = R. is the side of the triangular pin profile. 1. π. ω. τ..... a = π ω τ 9 (16) R = a H= H = ω. τ... R 0 H 0 R dx dy = = (17) π a θ= R = = ω. τ... θ 0 R 0 θ = = (18) R d dr From equations (16-18), T calculated as T = T =. π. ω. τ. +. R. H 4π (19) editor@iaeme.com

7 Study on effect of Tool Geometry on Energy and Temperature of Friction Stir Welding The energy per unit length of the weld calculated as dividing Equation (19) by weld speed (v) as ω. µ. F 9 =.... Energy length R + R H ν. R S 4 S π (0) D. Analytical Heat Generation Equation for entagonal in rofile Heat generation from shoulder surface is calculated by subtracting the heat generated due to probe tip () from the heat generated due to shoulder (S) where a = R / is the side of the pentagonal pin profile π. ω. τ a = π ω τ R = a H = H R probe = R ω τ dx dy ω τ a H = 0 H = = ω τ ω τ = a... a. H = a. H (1) () θ = π R = a 5 = ω. τ... θ 0 R 0 θ = = () R d dr From equations (1-), T = T calculated as.75 T =. π. ω. τ. +. R. H π (4) The energy per unit length of the weld calculated as dividing Equation (4) by weld speed (v) as ω. µ. F.75 Energy length = R H ν. π (5) E. Analytical Heat Generation Equation for Hexagonal in rofile Heat generation from shoulder surface is calculated by subtracting the heat generated due to probe tip () from the heat generated due to shoulder (S) where a = R is the side of the Hexagonal pin profile. 1. π. ω. τ..... a = π ω τ (6) R = a H = H a =.... =... = 0 R ω τ dx dy ω τ H R H = 0 = ω τ H... a. (7) editor@iaeme.com

8 Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar π. ω. τ. a. π. ω. τ. a π θ= R = a 6 = ω. τ... = = θ= 0 R = 0 θ R d dr 18 (8) 9 T =. π. ω. τ. +. R. H π (9) The energy per unit length of the weld calculated as dividing Equation (9) by weld speed (v) as ω. µ. F 9 =.... Energy length R + R H ν. R S S π (0). ENERGY AND TEMERATURE MODEL OF FSW CYLINDRICAL TOOL The main purpose of this paper is to derive the C ++ coding for the cylindrical tool profile to reduce the time consumption and easy to calculate the energy and the temperature of FSW tool. The various steps involved in the generation of C ++ programming are as follows: All the variable necessary to be declared in the calculation such as axial force (F), rotational speed (ω), welding speed (υ), shoulder diameter (R S), pin diameter (R ), pin height (H ) and solidus temperature (s). The local variables (a, b, c, d, e, f, g, h, j, k, l, m) for the calculation of energy and temperature. Generate equations. Verify the C coding. Generate the results. It is deal with the manual calculations and C ++ programming that scaling factor consideration have minor effect except the low energy levels. Flow chart for iterative solution of FSW as shown in Fig.. Figure Flow chart for iteration solution of FSW editor@iaeme.com

9 Study on effect of Tool Geometry on Energy and Temperature of Friction Stir Welding 4. RESULT AND DISCUSSION The energy model proposed in the above equations for both the frictional heating and the heating results from the plastic deformation. The effective energy per weld length ( Eff. ) [] defined as the energy per weld length multiplied by the transfer efficiency from following formulation where it takes into account the value of the height of the FSW tool probe (H) and the thickness of the work-piece (t). H =. = β. t Eff Energy length Energy length Where β be the coefficient of energy transfer efficiency, H is the height of the FSW tool and t is the thickness of the work-piece. For the proposed temperature model of the FSW tool probe, the empirical relationship developed by Hamilton et al. [] between the temperature ratio and effective energy level is considered. The empirical formula given as Tmax 4 = Eff T () Where T max the maximum temperature and T is the solidus temperature. The energy obtained by the numerical equation influence the temperature. Friction stir welding of IF Steel has conducted in butt weld configuration with a tungsten tool. The rectangular plates are 00 mm in length, 50 mm in width and 1.6 mm in thickness. The tool has a shoulder of 1 mm and a cylindrical pin of 1.4 mm length and 4 mm diameter. Thus, the length of the pin is slightly smaller than the workpiece thickness. The IF Steel used in the work contained 0.00% C, 0.079% Mn, % S, 0.006% Si, 0.059% Al, 0.00% N, % Ti and %. the thermo-physical properties of the IF steel and the tool material are given in Table 1. The coefficient of friction (µ) varies with temperature. However, in the present model for demonstration purpose it considered as Table 1 Data used in the calculations roperties / weld parameter Value roperties / weld parameter Value Workpiece length (x-direction) 00 mm Density 7870 kg/m Workpiece half-width (y-direction) 50 mm Frictional coefficient 0.49 Workpiece thickness 1.6 mm Axial force 6.65 kn Shoulder radius 6 mm Yield stress 17 N/mm in radius mm Heat transfer coefficient from bottom 51.9 W/m C in length 1.4 mm Tool material Tungsten Welding speed 100 mm/min Density 19,400 kg/m Tool rotational speed 400 rpm Solidus temperature of material 1800K Workpiece material IF Steel Table 1 describe about the various parameter such as thickness, tool geometry, welding speed, rotational speed and the applied normal force, energy and peak (maximum) temperature obtained using different pin profiles. From fig. 4, shows that energy generation and temperature of given pin profiles in increasing order of the edges increases from the triangular to hexagonal, the maximum heat generation for cylindrical pin profile as compared to other pin profile at constant welding parameters and tool rotation speed. The value of various parameters responsible for energy and temperature generation in FSW are tool rotational speed 400 rpm and welding speed 100 mm/min. (1) editor@iaeme.com

10 Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar Figure 4 Variation of (Energy/Length) with tool pin profiles Energy per unit length and peak temperature of the welds produced at rotational speed of range rpm and welding speed of range mm/min presented in figs. 5 & 6. Therefore, optimum parameter of welds from literature study produced at a welding speed of 100 mm/min and a rotational speed of 400 rpm, the same has proved in this paper. If tool rotational speed (more than 400 rpm) the peak temperature obtained is above 80 % of the melting point of base metal, will not consider for base materials. The computed energy and temperature increases with increase in the rotational speed because it becomes easier for the material to flow at higher temperatures. The design of the pin and shoulder assembly plays a major role on how the material moves during the process. The highest temperature what being produced in the FSW process is lower than the melting temperature of the work piece material, so joining of the material is achieved without melting. The form of the computed results agree well with the corresponding analytical results. Figure 5 Variation of (Energy/Length) with tool rotation speed of Cylindrical pin profile editor@iaeme.com

11 Study on effect of Tool Geometry on Energy and Temperature of Friction Stir Welding Fig. 6 Variation of (Energy/Length) with welding speed of Cylindrical pin profile Validation of the mathematical modelling The validation of the present mathematical model has been done by the peak temperature obtained experimentally [] for various welding speed with tool rotating speed to compute results in the present study. The computed values of peak temperature as a function of different welding speed at constant tool rotation speed presented in fig. 7 and found to be in good agreement with mathematical model Nandan et al []. Furthermore, validation of mathematical model carried forward by comparing the results from the numerical model with experimentally estimated results. Instead, a model validated of the FSW of a high carbon steel and subsequently used to understand the roles of important welding parameters on the peak temperature. Figure 7 Variation of welding speed with maximum temperature and energy at constant tool rotation speed 00 rpm editor@iaeme.com

12 Rajiv Ranjan Kumar, Shalendra Kumar and Ashok Kumar Sato et al. [4] have reported that the peak temperature exceeds 17 K during FSW of steels using W and CBN tools, although it is dependent on the welded material, welding parameters, tool material and tool geometry. Since the ACm temperature of the ultrahigh carbon steel used in this study is 1176 K, it is likely that the peak temperature during FSW is higher than the ACm temperature in the ultrahigh carbon steel. 5. CONCLUSIONS A detailed mathematical study have been carried out on the effect of tool pin profiles, tool rotation speed and welding speed on the formation of friction stir processing zone in interstitial free steel. The important conclusions of this study summarized as follows: A mathematical model has been successfully developed to compute heat generation in FSW of IF steel using different pin profile such as cylindrical, triangular, square, pentagonal and hexagonal pin profile. Using mathematical approach, it shows that by increasing the number of edges, the amount of heat generation increases from the triangular to hexagonal pin profile. The relationship has been developed to obtain the cylindrical pin is the maximum heat generate as compared to other pin profile. Furthermore, numerical modeling shows that increasing the tool rotation speed at constant welding speed, heat input increases, and increasing the weld speed at constant tool rotation speed, heat input decreases. A computer program in C ++ language developed to solve the mathematical model and obtained the results of energy and peak temperature in FSW. The usage of C ++ program minimized to calculate the number of equation substitution and solving. The peak temperature increases, increasing tool rotational speed at constant welding speed. Similarly increasing the weld speed at constant tool rotation speed, peak temperature decreases. A rotational speed of range rpm and welding speed of range mm/min used to fabricate the joints, the joints fabricated at a welding speed 100 mm/min and 400 rpm showed superior mechanical properties, irrespective of tool pin profile because of study on maximum temperature generated during FSW 80% of solidus temperature of base materials. REFERENCES [1] Singh, I., Singh, H., Chopra, A., 014. Effect of Tool Rotational Speed on Tensile and Impact Strength of Friction Stir Welded joints of Aluminum 606 Alloy. International Journal of Research in Mechanical Engineering and Technology. 4(), [] Yuh, J. Chao, X. i, W. Tang, (00), Heat transfer in friction stir welding- Experimental and Numerical Studies, Transaction of the ASME, Vol. 15, pp [] Ravindra S., Thube, Surjya K. al, 014. Influence of tool pin profile and welding parameters on Friction stir weld formation and joint efficiency of AA508 joints produced by Friction Stir Welding. International Journal of Innovation Research in Advanced Engineering. 1(4), 1-8. [4] Elangovan, K., Balasubramania, V., Babu, S., 009. rediction tensile strength of friction stir welded 6061 aluminum alloy joints by mathematical model. Materials and design. 0, [5] Ramanjaneyulu, K., Madhusudhan, Reddy G., Venugopal, rao A., Markandeya, R., 01. Structure-roperty Correlation of AA014 Friction Stir Welds: Role of Tool in rofile. Journal of Materials Engineering and erformance. (8), [6] Gadakh, V, S., Kumar, A., 014. Friction stir welding window for AA6061-T6 aluminum alloy. roc IMechE, art B: J Engineering Manufacture. 8(9), editor@iaeme.com

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