A fast and accurate two-stage strategy to evaluate the effect of the pin tool profile on metal flow, torque and forces in friction stir welding

摘要: Pin geometry is a fundamental consideration in friction stir welding (FSW). It influences the thermal behaviour, material flow and forces during weld reflects on joint quality. This work studies four pin tools with circular, triflute, trivex, triangular profiles adopting validated model of FSW process developed by authors. The effect rotating tool behaviour outcomes analysed. Additionally, longitudinal transversal torque are numerically calculated compared for different shapes. study carried out slip stick limiting cases between workpiece. The main novelties paper “speed-up” two-stage simulation methodology piecewise linear version constitutive model, both them conceived use real case industrial applications, where achievement accuracy affordable times importance. The Norton-Hoff adopted to characterize weld. authors greatly facilitates convergence numerical solution ensuring computational efficiency accuracy. A procedure applied. In first stage, forced transient out; second one, magnitudes interest computed. The shows that proposed modelling approach can be used predict interpret specific geometry. Moreover, reduction time using strategy up 90%, standard single stage strategy.