MATHEMATICAL MODEL FOR ANALYSIS OF HEAT TRANSFER IN FRICTION STIR WELDING

In this project firstly we started with the basic study of Friction Stir Welding (FSW) so as to develop the understanding of the welding process along with the principles and process parameters involved in this welding and as this is new technique patented in 1991, so we had a lot to deal with. We went through previous literatures and works that have been carried out so as to develop the understanding of Theoretical and Heat Transfer Modelling. We also carried out our study on the different heats generated and heat transfer mechanism in friction stir welding along with the different parameters affecting the heat generation and transfer in FSW. We further went through the different equations of heat transfer that are or can be involved in this welding process and tried to develop a mathematical model of this process considering the material and interface behaviours and friction as well. Finally transient temperature distribution during FSW of alloy was simulated using finite element modelling. The precise 3D finite element simulation of the Friction Stir Welding (FSW) process needed a proper information of both the materials and interface behaviours, but friction, the key phenomenon of this process is little bit difficult to modelling and identify. A three dimensional finite element model was developed on ABAQUS, the model was used to predict the peak temperature and analyse the thermal history during FSW. The model results were validated using the experimental results from the published literature mentioned in the reference [1].