International Journal of Engineering Trends and Technology (IJETT) – Volume 18 Number 6 – Dec 2014
Numerical Analysis for Finding the Parameters on Rotary Friction Welding of
Al-6063 T6
Akhil krishna A #1, S Marichamy*2, Al Faizal .B #3
#
PG Scholar, Assistant Professors, Mechanical Department, India
Abstract— A study of the friction welding process is carried out
for Al 6063-T6. 3D model of the rotary friction welding is made.
Thermo transient analysis and static structural analysis is
carried out. Friction welding with four different rpm (250, 500,
775, and 1200. The simulation process are carried out with
ANSYS workbench.
Keywords— Rotary friction welding, ANSYS workbench comma.
I. INTRODUCTION
Rotary friction welding, in which one component is rotated
against the other, is the most commonly used among the
processes, and many carbon steel vehicle axles and subaxles
are assembled in this way. The process is also used to
fabricate suspension rods, steering columns, gear box forks
and drive shafts, as well as engine valves, in which the ability
to join dissimilar materials means that the valve stem and head
can be made of materials suited to their different duty cycles
in service. Traditionally, friction welding is carried out by
moving one component relative to the other along a common
interface, while applying a compressive force across the joint.
The friction heating generated at the interface softens both
components, and when they become plasticised the interface
material is extruded out of the edges of the joint so that clean
material from each component is left along the original
interface. The relative motion is then stopped, and a higher
final compressive force may be applied before the joint is
allowed to cool. The key to friction welding is that no molten
material is generated, the weld being formed in the solid state.
The principle of this process is the changing of mechanical
energy into heat energy. One component is gripped and
rotated about its axis while the other component to be welded
to it is gripped and does not rotate but can be moved axially to
make contact with the rotating component. At a point fusion
temperature is reached, then rotation is stopped and forging
pressure is applied. Then heat is generated due to friction and
is concentrated and localized at the interface, grain structure is
refined by hot work. Then welding is done, but there will not
occur the melting of parent metal.
Briefly the friction-welding process consists in bringing
into contact two elements to be welded while one of the two is
static and the other is rotated rapidly on its axis. As the soon
as the heat generated by attrition at the interface is sufficient
for solid state welding without melting, the rotation is stopped
and the elements are forced together under pressure producing
local forging which concludes the intimate joining and also
expels at the joint all surface contamination and some of the
upset material called flash.
ISSN: 2231-5381
II. OBJECTIVE
A detailed study of the friction welding process is to be
carried out, 3D model of the rotary friction welding is to be
made. Thermo transient analysis and static structural analysis
is to be carried out and FW joints with different rpm (250, 500,
775, and 1200).
Numerical simulation of welding process is to be modelled
using solid works and is converted to ANSYS to gain the
temperature field and finding strong friction welded joints for
different rpm are to be obtained within the given parameters.
III. LITERATURE REVIEW
Ranjitsinh D. Jadeja et al [1] 2012. Develop a finite
element simulation of friction stir welding of AA6063-T6
Aluminium alloy. Dr.K.P.Narayanan et al [2] 2013. Study on
aluminium alloys. Strong friction welded joints for different
surface interfaces were obtained and mechanical characteristic
studies of the same were carried out. Biswajit Parida et al [3]
2012. Study of Mechanical properties and study of microstructural properties of Al-Alloy. Wichai Pumchan [4] 2011.
The experimental application of a friction stir welding of the
butt joints between aluminium AA6063 and AA7075 by
changing the parameter. Ali. Moarrefzadeh [5] 2011.
Numerical simulation of welding process in SIMPELC
method and by ANSYS software for gaining the temperature
field of carbon steel, the effect of parameter variation on
temperature field and process optimization for different cases
of electrode done. Pasquale Cavaliere [6] 2013. The fatigue
life and crack behaviour of several aluminium alloys FSW
joints have been presented. V. Balasubramanian et al [7] 2012.
The FSW process parameters such as, the tool rotational speed,
the welding speed and the axial force play a major role in
deciding the weld quality. Vivekanandan. P et al [8] 2012.
The influence of friction stir welding on the microstructure
and hardness of aluminium 6035 and 8011. P.John Maclins [9]
studied the effect of corrosion and low impact damage on
aluminium alloy 6063- T6.
IV. MODELLING
A. Model Creation
As the rotary welding process can be modelled with
solidworks 2014, an Axisymmetric 3D model of Al 6063-t6
rods of dimensions as per ASTM Standard tensile specimen
(fig 4) was made with symmetry about the Y axis. The model
was meshed with 3830 nodes and elements 1956 and two
displacement degrees of freedom in the X and Y directions
respectively. The thermal effect of friction welding process
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International Journal of Engineering Trends and Technology (IJETT) – Volume 18 Number 6 – Dec 2014
depends on the friction type and melting point of the work
piece. Numerical simulation of welding process by ANSYS
software for gaining the temperature field of Al 6063 alloy
and find out the weld strength and quality of the weld with
different rpm
since heat generation takes place during welding
process which is equal to 600°C and the ends of
two rods are given a temperature of 22°C (position
“B” marked on fig 3.7) assuming to be the
atmospheric temperature.
Fig. 1 Meshing of model, model is designed using solidworks and import it
to the ansys workbench. Tetrahedral element was used for meshing.
B. Static Structural for 1200, 775, 500 and 250 RPM
Fig. 2 Boundary condition for static structural analysis for 1200, 775,500 and
250 rpm.
A 1200,775,500 and 250 rpm is being applied to the part
connected with the head stock (i.e. at position “A” marked on
fig 2). The model is constrained by arresting rotation of
stationary specimen and axial movement of rotating specimen.
This is done by arresting X direction motion at the end nodes
of stationary specimen and Y direction motion at the end node
of rotating specimen. At contact surface of two parts make an
axial movement by giving free movement along y- axis and
also arresting movement along x and y axis. A pressure of
10MPa is applied at the constrained end of the stationary
specimen (i.e. at position “E” marked on fig 2).
C. Transient Thermal Analysis
A temperature load of 600°C (position “A”
marked on fig 3.7) was given at the contact nodes
ISSN: 2231-5381
Fig. 3 Boundary condition for thermal analysis for 1200,775,500, 250 rpm
Fig 4 ASTM Standard tensile specimen (All dimensions are in mm)
Fig 4. Represents specimen prepared from these combinations
as per ASTM standards (B557M) [9].
V. RESULTS AND DISCUSSION
A. Equivalent Stress
The Von Mises stress values at the initial stage
seemed to be maximum on areas away from the
constrained end regions with a value of 8.6654 MPa.
Towards the end of the process the Von Mises
stress was found to be maximum on end of rotating
work piece with a value of 14.93 MPa. At the initial
stage as well as in the final stage the minimum
value of Von Mises stress was obtained at the heat
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International Journal of Engineering Trends and Technology (IJETT) – Volume 18 Number 6 – Dec 2014
affected zone of specimen with a value of 5.22 MPa
for weld at 775,500,250 rpm and 9.66 MPa for
1200 rpm At the welding interface (the contact
region) the value of von-Mises stress is less than the
stress obtained at other regions.
C. Directional Deformation
Fig. 7 Directional deformation at welded joint
Directional deformation along y-axis is shown in
fig 7 the job is symmetric along y-axis. From the
obtained result shows maximum deformation is
occurred at weld joint 250 rpm with 9 mm this is
due to the increases in contact pressure and time
consuming for reaching its weld temperature at
contact surface.
Fig. 5 Equivalent stress at welded joint
B. Elastic Strain
TABLE I
PERCENTAGE SHRINKAGE AFTER WELDING PROCESS BY USING
SOFTWARE
Original
Change in
length (mm)
length (mm)
Welded with 1200 rpm
240
1.9
Welded with 775 rpm
240
3.5
Welded with 500 rpm
240
7.2
Welded with 250 rpm
240
9
Test series description
Fig. 6 Elastic strain at welded joints
The strain rate is an important physical parameter
during welding process. Therefore, the analysis was
carried out to consider the strain rate distributions
in the friction welding process. The most
deformation that occurred in the interface was as a
result of high transient temperature and subsequent
material flowing. Figure 6 shows the strain rate
distributions for friction welding of Al6063-T6
alloy with different 1200,775, 500 and 250 rpm.
ISSN: 2231-5381
D. Contact Pressure Distribution
Flash formation is mainly depend on contact pressure at
weld zone from fig 8 shows contact pressure distribution at
weld zone. With Increases in rotational velocity of job results
decrease in contact pressure. If more contact pressure results
more flush will be form that will reduce the length of job. Fig
7 shows change in length of job with different rpm. From the
ansys result it is clear that more flush will form at job with
250 rpm because of increases in contact pressure value of
28.42MPa as compared with other job with rpm of 1200,775
and 500.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 18 Number 6 – Dec 2014
[3].
[4].
[5].
[6].
[7].
Fig. 8 Contact pressure distribution at weld zone for 1200 rpm welded joint
E. Total Heat Flux
[8].
The maximum total heat flux of the specimen is found to
5.16 W/〖mm〗^2 at one second is shown in figure 9
[9].
[10].
[11].
[12].
[13].
[14].
Fig. 9 Total heat flux for welded joints.
VI. CONCLUSIONS
The results shows that the weld zone is stronger than the
base metals since the rupture occurred outside of the welding
area. The quality of rotary friction welding is depend on
rotating velocity of members. In this study it is clear that at
high rpm material binds together due to high material
penetration and hence length of the workpiece is reduced after
welding. The weld zone was divided into three regions based
on the microstructure (center of weld and two HAZ). The
center of weld had fine grains due to dynamic recrystallization
with higher tensile strength and hardness. The study reveals
that for Al 6063-T6 after friction welding at 250 rpm the
mechanical properties are reduced. This shows that the speed
of rotating member affect the quality of weld.
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