fsw analysis

7/25/2019 FSW analysis

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Heat Flow Analysis inFriction Stir Welding

Project Guide:- Prof. R P Vyasa

Prepared y:-

!a"e #$in%ay &'((')(''*((+,

S$ula alay &'((')(''*('+,

/odi Pooja &'((')(''*(+',

Vala 0iyati &'((')(''*(+1,


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istory

Friction Stir Welding was invented at 2W3 (The Welding

Institute), England in the year 1991.

Friction Stir Welding is a solid-state rocess, in which the

o!"ects are "oined !elow the #elting oint with the hel o$

ressure.

%eating !y the $riction !etween rotating tool and wor&

iece.

The heat generated in the "oint area is tyically a!out

'-9 o$ the #elting te#erature.


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Key Features

Solid state rocess

*ow ther#al distortion

+ood di#ensional sta!ility

o loss in alloying ele#ents

Ecellent #etallurgical roerties

Fine #icro structure

4n"iron%ental friendly hence called green welding technology

o shielding gas

o use o$ che#ical $or cleaning o slag and $u#es

%ighly energy e$$icient


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Schematic Diagram of FSW


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Section Of FSW Process


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Methods Of FEA


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Project Procedure


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WORK COMPE!ED


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!ransient Structura"

Ana"ysis

esh +eneration

/e$or#ation


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Static eat Source

Ana"ysis

esh +eneration

Te#erature 0ontours


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Mo#ing eat Source

Ana"ysis

!i%ensions:

late233 ##

Thic&ness o$ late24 ##

ro!e /i#enstion25 ##Tool 6otation2 .5 rad7s

Assu%ptions:

Flow velocity .3#7s

*a#inar $low o$ #aterial

Side walls are Insulated


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Mo#ing eat Source

Ana"ysis

Residue 5f #alculation


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Mo#ing eat Source

Ana"ysis

2e%perature #ontour on Plane 2e%perature Gradient #ontour
http://var/www/apps/conversion/tmp/scratch_1/fsw.avi


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Mo#ing eat Source

Ana"ysis

2e%perature Strea%line Velocity Strea%line


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!endency of

F"uid$Meta"% &artic"es

Due to !oo"Rotation


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!em&erature 'radient

Chart
http://var/www/apps/conversion/tmp/scratch_1/temp_cont1.mpeg


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!em&erature (s )

Direction

Te#erature /istri!ution on line arallel to tool #ove#ent near!y the tool location
http://var/www/apps/conversion/tmp/scratch_1/sequence-2.mpeg


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APD Code for the

mo#ing eat source
http://var/www/apps/conversion/tmp/scratch_1/FFF-21-00060.dat.wmv


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APDL Program


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e* Mesh

'enerated


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oad at +ode
http://var/www/apps/conversion/tmp/scratch_1/ALL%20Done.txthttp://var/www/apps/conversion/tmp/scratch_1/ALL%20Done.txt


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Mo#ing eat Source

*in&-1 *in&-5

*in&-8
http://var/www/apps/conversion/tmp/scratch_1/apdl%20program.txt


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E*&erimenta" Wor,

done at

SO!-PDP.

under the guidance

of

Dr/ (ish#esh

0adhe,a


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http://var/www/apps/conversion/tmp/scratch_1/VID_20140501_123817.mp4http://var/www/apps/conversion/tmp/scratch_1/VID_20140501_002838.mp4http://var/www/apps/conversion/tmp/scratch_1/MOV_0027.mp4


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!em&erature 'ra&h

1y A+S2S

0

50

100

150

200

250

Temperature

Temperatur

e


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E*&eriment

!em&erature 'ra&h

0

50

100

150

200

250

300

Temperature

Temperature


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Com&arision Of

E*&erimenta" Data And

Ansys Data


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!em&erature Data

Across !he We"d ine

At Midd"e Of P"ate At

!ime 3 454/6


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Conc"usion

The seci$ied contours o$ te#erature distri!ution are generated so we canesti#ate the te#erature at that articular and its near!y that locations.

The velocity distri!ution o$ #etal $low near the weld nugget is also so#ewhat

revealed.

Te#erature contour also oints out that the te#erature distri!ution at

advancing side and retreating side is di$$erent. Te#erature gradient contour on a horiontal lane has revealed the

te#erature ro$ile !e$ore and a$ter welding oeration.

Te#erature distri!ution and #otion o$ te#erature ro$ile is revealed.

0o#arison o$ eeri#ental and analytical result data shows that 1-5

variation in te#erature occurs in :nsys data and Eeri#ental data.

Te#erature distri!ution at any instant o$ ti#e erendicular to weld line can

!e &nown $or any location.


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Plate Deformation


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!han, 2ou

fsw analysis

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