Simulation Of Bobbin Friction Stir Welding Using Deform-3D

Bobbin Friction Stir Welding is a relatively new solid-state process and a variation of Friction Stir Welding (which was invented and patented by The Welding Institute) that distinguishes itself in terms of tool structure, characteristics and advantages. Despite the lack of sufficient understanding...

Full description

Saved in:

Bibliographic Details
Main Author:	Mohammed AbdulGhaffar, Firas Ahmed
Format:	Thesis
Language:	English English
Published:	2018
Subjects:	T Technology (General) TS Manufactures
Online Access:	http://eprints.utem.edu.my/id/eprint/23884/1/Simulation%20Of%20Bobbin%20Friction%20Stir%20Welding%20Using%20Deform-3D.pdf http://eprints.utem.edu.my/id/eprint/23884/2/Simulation%20Of%20Bobbin%20Friction%20Stir%20Welding%20Using%20Deform-3D.pdf
Tags:	Add Tag No Tags, Be the first to tag this record!

id	my-utem-ep.23884
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
topic	T Technology (General) TS Manufactures
spellingShingle	T Technology (General) TS Manufactures Mohammed AbdulGhaffar, Firas Ahmed Simulation Of Bobbin Friction Stir Welding Using Deform-3D
description	Bobbin Friction Stir Welding is a relatively new solid-state process and a variation of Friction Stir Welding (which was invented and patented by The Welding Institute) that distinguishes itself in terms of tool structure, characteristics and advantages. Despite the lack of sufficient understanding of this process, Bobbin Friction Stir Welding is known to surpass conventional welding because its double-sided feature contributes to low thermal distortion, reduces down force, eliminates root causes and produces better quality welds with strong mechanical structure. Bobbin Friction Stir Welding tool consists of two cylindrical shoulders connected by a pin, all of them contact the work-piece. The tool penetrates two joined metal plates at the joint-line, which heats the material. When plastic state is achieved, the softened material of the each plate is mixed with the other, forming a solid bond at the solid state. There is still a relative shortage of literature concerning the mechanism of this process. Therefore, the goal was to contribute to the existing research findings by investigating this welding process. The objective of this project was to analyze temperature behavior and flow of work-piece material during the welding process at different welding parameters, utilizing Finite Element Analysis and DEFORM-3D software for simulation, and validate the results by comparison with previous study. A three-dimensional, Finite Element Model of the bobbin friction stir welding tool and work-piece was developed and evaluated using DEFORM-3D software tool. Welding speeds were varied throughout the simulation, and the simulation results were compared with those obtained by previous researchers. Additionally, several past studies on the subject of both conventional and bobbin friction stir welding were analyzed for validation purposes. The findings of this analysis revealed that temperature profile was symmetric along the X-Y axis as the tool moves along the work-piece, while in the X-Z section it exhibited symmetry of wide distribution at the surfaces of the work-plates and narrow radius about the mid-thickness, forming a „waist shape‟. Furthermore, the findings also indicated that sufficient welding temperature was achieved slower when the welding speed increased in each simulation run. Finally, the plastic material was observed to form a tail as it flowed outward towards the rear of the work-piece. These observations were reinforced and validated by other similar studies.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mohammed AbdulGhaffar, Firas Ahmed
author_facet	Mohammed AbdulGhaffar, Firas Ahmed
author_sort	Mohammed AbdulGhaffar, Firas Ahmed
title	Simulation Of Bobbin Friction Stir Welding Using Deform-3D
title_short	Simulation Of Bobbin Friction Stir Welding Using Deform-3D
title_full	Simulation Of Bobbin Friction Stir Welding Using Deform-3D
title_fullStr	Simulation Of Bobbin Friction Stir Welding Using Deform-3D
title_full_unstemmed	Simulation Of Bobbin Friction Stir Welding Using Deform-3D
title_sort	simulation of bobbin friction stir welding using deform-3d
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2018
url	http://eprints.utem.edu.my/id/eprint/23884/1/Simulation%20Of%20Bobbin%20Friction%20Stir%20Welding%20Using%20Deform-3D.pdf http://eprints.utem.edu.my/id/eprint/23884/2/Simulation%20Of%20Bobbin%20Friction%20Stir%20Welding%20Using%20Deform-3D.pdf
_version_	1747834057041903616
spelling	my-utem-ep.238842022-03-17T08:43:02Z Simulation Of Bobbin Friction Stir Welding Using Deform-3D 2018 Mohammed AbdulGhaffar, Firas Ahmed T Technology (General) TS Manufactures Bobbin Friction Stir Welding is a relatively new solid-state process and a variation of Friction Stir Welding (which was invented and patented by The Welding Institute) that distinguishes itself in terms of tool structure, characteristics and advantages. Despite the lack of sufficient understanding of this process, Bobbin Friction Stir Welding is known to surpass conventional welding because its double-sided feature contributes to low thermal distortion, reduces down force, eliminates root causes and produces better quality welds with strong mechanical structure. Bobbin Friction Stir Welding tool consists of two cylindrical shoulders connected by a pin, all of them contact the work-piece. The tool penetrates two joined metal plates at the joint-line, which heats the material. When plastic state is achieved, the softened material of the each plate is mixed with the other, forming a solid bond at the solid state. There is still a relative shortage of literature concerning the mechanism of this process. Therefore, the goal was to contribute to the existing research findings by investigating this welding process. The objective of this project was to analyze temperature behavior and flow of work-piece material during the welding process at different welding parameters, utilizing Finite Element Analysis and DEFORM-3D software for simulation, and validate the results by comparison with previous study. A three-dimensional, Finite Element Model of the bobbin friction stir welding tool and work-piece was developed and evaluated using DEFORM-3D software tool. Welding speeds were varied throughout the simulation, and the simulation results were compared with those obtained by previous researchers. Additionally, several past studies on the subject of both conventional and bobbin friction stir welding were analyzed for validation purposes. The findings of this analysis revealed that temperature profile was symmetric along the X-Y axis as the tool moves along the work-piece, while in the X-Z section it exhibited symmetry of wide distribution at the surfaces of the work-plates and narrow radius about the mid-thickness, forming a „waist shape‟. Furthermore, the findings also indicated that sufficient welding temperature was achieved slower when the welding speed increased in each simulation run. Finally, the plastic material was observed to form a tail as it flowed outward towards the rear of the work-piece. These observations were reinforced and validated by other similar studies. 2018 Thesis http://eprints.utem.edu.my/id/eprint/23884/ http://eprints.utem.edu.my/id/eprint/23884/1/Simulation%20Of%20Bobbin%20Friction%20Stir%20Welding%20Using%20Deform-3D.pdf text en public http://eprints.utem.edu.my/id/eprint/23884/2/Simulation%20Of%20Bobbin%20Friction%20Stir%20Welding%20Using%20Deform-3D.pdf text en validuser http://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=113627 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering 1. Amin, S. A., Hanna, M. Y. and Mohamed, A. F., 2018. Modeling and Optimization of Bobbin Friction Stir Welding for AA6061-T6 alloy Utilizing Response Surface Methodology. Journal of University of Babylon, Engineering Sciences, pp. 1–17. 2. Babu A, S. and Chockalingam, D., 2013. An Overview of Friction Stir Welding. International Journal of Research in Mechanical Engineering & Technology, pp. 259–265. 3. Bathe, K.-J., 2014. Finite Element Procedures. Available at: http://web.mit.edu/kjb/www/Books/FEP_2nd_Edition_4th_Printing.pdf. 4. Chaudhary, S. S. and Bhavsar, K. H., 2016. A Review of Bobbin Tool Friction Stir Welding ( FSW ) Process. International Journal of Science Technology & Engineering, pp. 630–633. 5. Chen, S., Li, H., Lu, S., Ni, R., Dong, J., 2015. Temperature measurement and control of bobbin tool friction stir welding. 6. Das, B., Pal, S. and Bag, S. 2016. Defect Detection in Friction Stir Welding Process Using Signal Information and Fractal Theory. Procedia Engineering, pp. 172–178. 7. Esmaily, M., Mortazavi, N., Osikowicz, W., Hindsefelt, H., Svensson, J. E., Halvarsson, M., Thompson, G. E., Johansson, L. G., 2016. Corrosion behaviour of friction stir-welded AA6005-T6 using a bobbin tool. Evaluation and Program Planning. Elsevier Ltd. 8. Essa, A. R. S., Ahmed, M. M. Z., Mohamed, A. Y. A., El-Nikhaily A. E., 2016. An analytical model of heat generation for eccentric cylindrical pin in friction stir welding. Journal of Materials Research and Technology. Korea Institute of Oriental Medicine, pp. 234–240. 9. Fraser, K. A., 2014. Numerical Simulation of Bobbin Tool Friction Stir Welding. Conference paper, pp. 1–15. 10. Hilgert, J., Hütsch, Leon L., Santos, J. F., Huber, N., 2010. Material Flow around a Bobbin Tool for Friction Stir Welding. COSMOL Conf 2010 Paris, p. 4152. 11. Hilgert, J., 2012. Knowledge Based Process Development of Bobbin Tool Friction Stir Welding. pp. 2191–78. 12. Hussein, S. A., Thiru, S., Izamshah, R., Tahir, A. M., 2014. Unstable Temperature Distribution in Friction Stir Welding. Advances in Materials Science and Engineering. 13. Iordache, M., Badulescu, C., Iacomi, D., Nitu, E., Ciuca, C., 2016. Numerical Simulation of the Friction Stir Welding Process Using Coupled Eulerian Lagrangian Method. IOP Conference Series: Materials Science and Engineering. 14. Jain, R., Pal, S. K. and Singh, S. B., 2014. Finite Element Simulation of Temperature and Strain Distribution in Al2024 Aluminum Alloy by Friction Stir Welding. 5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014), pp. 3–7. 15. Ji, S., Jin, Y., Yue, Y., Zhang, L., Lv, Z., 2013. The effect of tool geometry on material flow behavior of friction stir welding of titanium alloy. Engineering Review, pp. 107–113. 16. Kang, S.-W. and Jang, B.-S., 2014. Comparison of friction stir welding heat transfer analysis methods and parametric study on unspecified input variables. Journal of Mechanical Science and Technology, pp. 4233–4246. 17. Khalkhali, A. and Saranjam, M. J., 2015. Finite element simulation of microstructure evolution during friction stir welding of automotive aluminum parts. International journal of automotive engineering. 18. Kheireddine, A. H., Khalil, A. A., Ammouri, A. H., Kridli, G. T., Hamade, R. F., 2013. An experimentally validated thermo mechanical finite element model for friction stir welding in carbon steels. Icaim, pp. 2–5. 19. Liu, F. C., Hovanski, Y., Miles, M. P., Sorensen, C. D., Nelson, T. W., 2017. A review of friction stir welding of steels: Tool, material flow, microstructure, and properties. Journal of Materials Science and Technology. The editorial office of Journal of Materials Science & Technology, pp. 39–57. 20. Liu, X. M., Yao, J.S., Zou, Z.D., Cai, Y., Meng, H., 2014. Finite Element Analysis for Bobbin Tool Friction Stir Welding. TELKOMNIKA Indonesian Journal of Electrical Engineering, pp. 4854–4860. 21. Mijajlovi, M., Mileie, D., Nikolie-Stanojevic, V., Mileie, M., 2012. Numerical Simulation of Friction Stir Welding on Aluminum Alloy 2024-T351 Plates. Scientific Publications of the state university of Novi pazar, p. 6. 22. Mimouni, O., Badji, R., Hadji, M., Kouadri, D. A., Rachid, H., Chekroun, N., 2016. Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding 2017A Aluminum Alloys. MATEC Web of Conferences. 23. Philip, P., 2018. Numerical Analysis. LMU Munich, p. 6. 24. Raju, B. P. and Swamy, M. K., 2012. Finite Element Simulation of a Friction Drilling process using Deform-3D. International Journal of Engineering Research and Applications, pp. 716–721. 25. Rambabu, G., Balaji Naik, D., Venkata Rao, C. H., Srinivasa Rao, K., Madhusudan Reddy, G., 2015. Optimization of friction stir welding parameters for improved corrosion resistance of AA2219 aluminum alloy joints. Defence Technology, pp. 330–337. 26. Sahidi, S. B., 2013. FRICTION STIR WELDING OF DISSIMILAR METAL. 27. Scupin, P., 2015. Semi-Stationary Shoulder Bobbin Tool ( S 3 BT ): A New Approach in High Speed Friction Stir Welding. 28. Shanmuga, S. N., Murugan, N. and Suresh, S., 2011. Mathematical Modeling of Ductility of Friction-Stir-Welded AA5083-H321. International Journal of Material Research, Electronics and Electrical Systems. 29. Sharma, D. and Bhushan, R. K., 2013. Thermomechanical Modeling of FSW : A Review, pp. 130–135. 30. Singh, B. R., 2014. A Hand Book on Friction Stir Welding Late Shri Ram Yagya Singh. 31. Singh, P., Biswas, P. and Kore, S. D., 2016. A three-dimensional fully coupled thermo- mechanical model for Self-reacting Friction Stir Welding of Aluminium AA6061 sheets. Journal of Physics. 32. Sued, M. K., 2015. Fixed Bobbin Friction Stir Welding of Marine Grade’, University of Canterbury. 33. Tamadon, A., Pons, D.J., Sued, K., Clucas, D., 2018. Formation mechanisms for entry and exit defects in bobbin friction stir welding. Metals, pp. 1–22. 34. Tamizharasan, T. and Kumar Senthil, N., 2014. Numerical simulation of effects of machining parameters and tool geometry using DEFORM-3D: Optimization and experimental validation. World Journal of Modelling and Simulation, pp. 49–59. 35. Veljić, D., Perović, M., Sedmak, A., Rakin, M., Bajić, N., Medjo, B., Dascau, H., 2011. Numerical Simulation of the Plunge Stage in Friction Stir Welding. Romania, pp. 131–134. 36. Vijayakumar, R., Kannan, V. and Natarajan, A., 2017. Friction Stir Welding of Aluminium Alloys. Aluminium Alloys - Recent Trends in Processing, Characterization, Mechanical Behavior and Applications. 37. Xu, W., Zhang, W., Wu, X., 2017. Comparative study on local and global mechanical properties of bobbin tool and conventional friction stir welded 7085-T7452 aluminum thick plate. Journal of Materials Science and Technology, pp. 173–184. 38. Yisong, W., Jianhua, T., Congqing, L., Guohong, L., 2012. Application of Friction Stir Welding on the Large Aircraft Floor Structure. 9th International Friction Stir Welding Symposium. 39. Zapata, J., Valderrama, J., Hoyos, E., Lopez, D., 2013. Mechanical Properties Comparison of Friction Stir Welding Butt Joints of Aa1100 Made in a Conventional Milling Machine and a Fsw Machine’, Dyna-Colombia, pp. 115–123. 40. Zhuo, C., Lu-fang, Q. I. N. and Li-juan, Y. (2015) ‘Cutting Force Simulation of Titanium based on DEFORM-3D’, (Ic3me), pp. 1846–1849.

Simulation Of Bobbin Friction Stir Welding Using Deform-3D

Similar Items