“STRESS & STRAIN ANALYSIS IN FRICTION STIR WELDING WITH THE

ANSYS TOOL”

PRESENTED BY :-NANDAN KR SINGH

DEEPAK KUMARNIRAJ KUMAR

GAURAV VERMA

WHAT IS FRICTION STIR WELDING?

• Solid-state welding technique • Joining of metals without filler materials• FSW process takes place in the solid phase below the melting

point of the materials to be joined. • FSW is a solid state joining process• Welding using friction as the major resource Welds created by,

a) Frictional heating

b) Mechanical deformation

•

Where it is Utilized….

• AIRCRAFT • AUTOMOBILES

Utilization continued….

• RAILWAYS • SHIP BUILDING

Advantages

Good mechanical properties as in weld

condition

Improved safety due to absence of toxic fumes

No consumables

Easily automated on simple milling machines

Can operate on all positions

Low environment impact

High superior weld strength

Recognition of need

• contribute to the development of fields in design, intelligent machining, mechatronics and materials research.

• FSW will assist in establishing FSW as a more acceptable joining technique.

Background of FSW• Invented and patented in Cambridge at TWI

(The Welding Institute of UK) in 1991.• A US patent for FSW, # 5,460,317, was filed in

November 1992 with W. H. Thomas et al as inventors, assigned to TWI. A number of companies around the world are using the process in production, primarily for joining aluminium.

Working Process:

FSW process involves four phases which are: • Plunging phase, • Dwelling phase, • Welding phase, and finally • Exit or retract phase. Briefly, the process

starts with rotating .

Working principle of FSW process:

Process Parameter:

• Tool rotation and traverse • Tool tilt and plunge depth• Tool design • Welding forces • Flow of material

Problem Statement

To develop a FSW facility for analysis of the strain & stress of friction stir welded joints.

Objective

• To analyse the different types of stresses in the process of friction stir welding like, Equivalent (Von -Misses), maximum principal stress, pressure intensity etc.

• To Converse conventional friction stir welding to a ANSYS friction stir welding process

• To design and development of a tool

Objective continued…….

• To design and develop of clamping surfaces and backing plates to support

• To investigate, evaluate and control of process welds

• To determine and evaluate the weld capabilities and performance of the FSW facility

Research Methodology• Investigation and development of criteria describing the welding

process and basic procedure.• Establishment of important parameters to create a friction stir

weld(feed range, vertical force, material, tool sizes, angular velocity )

• Design of a tool tip.• Design of clamping devices to ensure stability and accuracy of the

welding process. • Conversion and development of a conventional friction stir welding

into a Ansys Friction stir welding unit.• Creating successive butt welds on Al & Cu plates by using Ansys

technology.• Monitoring certain parameters such as weld temperature, process

speed, axial force and vibration.

Work Piece Details

Aluminium alloys of AA6061-T651 and AA7075-T651 were selected for fabricating dissimilar joints using the FSW process. The thicknesses of both plates were 6.35mm. The plates were in a butt joint configuration and the welding process was carried out normal to the rolling direction of the plates. The dimensions of the aluminium plates are 200mmlength and 80mm width. The chemical compositions of AA6061 T-651 and AA7075 T651 are given in Tables I & Table II shows the mechanical properties of the base metals.

SOLVING TECHNIQUE ANSYS :-ANSYS is an engineering simulation software (computer-aided engineering, or CAE)

FLOW CHART OF SOLVING TECHNIQUE

PREDICTED MODEL

MESHING OF MODEL

Geometrical model for FSW process with force

Geometrical model for FSW process with tool velocity

Geometrical model for FSW process with tool angular velocity

Equivalent (von-mises) stress

NORMAL ELASTIC STRAIN

GRAPHICAL OUTPUT NORMAL ELASTIC STRAIN

DIRECTIONAL DEFORMATION:

CONCLUSION

These studies are done on the basis of FSW process and observes several data related to stresses like, Equivalent (Von-Mises), maximum principal stress and maximum shear stress during the process. According to these data we can easily analyse that the welding process done by FSW is better than the other welding method with respect to strength.

FUTURE WORK

The future outlook of the process is very promising with new interest on its recent development that allows broader application in term of material used as well as process improvement. In addition, the development of mathematical analysis provides the ability to predetermine the effect of parametric study of the process effect on the work material at a shorter time as well as to be adapted to process automation.