Generic placeholder image

Current Materials Science

Author(s): Qiang Wan* and Zheng Xiong

DOI: 10.2174/2666145416666221129143325

DownloadDownload PDF Flyer Cite As
Simulation Analysis of Stir Tool Wear Considering the Effect of Temperature Rise caused by Material Deformation on Flow Stress

Page: [225 - 234] Pages: 10

  • * (Excluding Mailing and Handling)

Explore Articles
About Journal
For Authors
For Editors
For Reviewers

Abstract

Background: Wearing is a prominent problem in friction stir welding. The material flow stress equation is a key factor that decides the accuracy of the simulation of the wearing process.

Objective: We aim to propose a material flow stress equation based on material true stress and true strain curve, which takes proper factors into account and leads to good accuracy in numerical simulation of stir tool wear.

Methods: The value of the material temperature rise caused by the material deformation heat and the value of the effect caused by the temperature rise on flow stress was calculated, and the effect value was used to modify the material flow stress and the related curve, and then the modified flow stress equation was obtained. On this basis, the equation was used to simulate the stir tool wear, and the simulation results were compared with those results without considering the effect of temperature rise.

Results & Discussion: the wear amount of the stir needle when considering the effect of temperature rise is significantly less than that when the effect of temperature rise is not considered.

Conclusion: In the simulation of the wear of the stir tool, it is necessary to adopt the modified flow stress equation considering the effect of temperature rise.

Keywords: Stir tool wear, simulation analysis, flow stress equation, material deformation, temperature rise effect, stress-strain curve.

Graphical Abstract

[1]
Luan YT. Damage mechanisms and lifetime prediction of stir head for FSW. PhD thesis; Northeastern University 2015.
[2]
Ji PF, Zhang Z, Zhao GH, et al. Research progress of stirring tool for friction stir welding. Aerospace Mater Technol 2020; 50(30): 56-61.
[3]
Shao S, Huang YD, Chen YH. Research status on tools of friction stir welding in titanium alloy. J Netshape Form Eng 2019; 11(5): 115-22.
[4]
Li XN, Wu W. Research on pin tool wear mechanism based on finite element. Hot Work Technol 2014; 43(07): 212-4.
[5]
Tan ZJ, Wu Q, Zhang Z. Numerical simulation of tool wear in friction stir welding of different aluminum alloys. Hot Work Technol 2017; 46(07): 206-9.
[6]
Chen ZF, Wang QX, Wang M, et al. Finite element analysis of mixing tool wear considering temperature effect. Transac China Weld Instit 2019; 40(01): 109-12.
[7]
Zeng S, Chang HP, Zhang J, et al. Study on high-temperature rheological behavior and constitutive model for A356 aluminum alloy. Forg Stamp Technol 2022; 47(4): 242-8.
[8]
Chen YS, Sun XM, Ji ZS, et al. Flow stress and dynamic recrystallization behavior of squeeze-cast AZ91D alloy. Zhongguo Youse Jinshu Xuebao 2022; 32(3): 721-30.
[9]
Qiao SB, He XK, Liu JJ, et al. Microstructure evolution and flow stress modeling of SA508Gr.4N steel during hot deformation process. J Mater Eng 2021; 49(3): 67-77.
[10]
Chen XW, Zhang JY, Huang T, et al. Flow stress model of 2A12 aluminum alloy based on modified Voce mode. Transac Mater Heat Treat 2019; 40(6): 170-6.
[11]
Xiao G, Li LX, Ye T. Modification of flow stress curves and constitutive equations during hot plane compression deformation of 6013 aluminum alloy. Zhongguo Youse Jinshu Xuebao 2014; (5): 1268-74.
[12]
Tang WS, Yang XQ, Zhao HH. Numerical analysis of stationary shoulder friction stir welding process for aluminum alloy thick-plate. Aeronaut Manufactur Technol 2020; 63(11): 41-9.
[13]
Pan Y. Study on the shape and wear of FSW tool based on fully coupled thermo-mechanical modeling. Dalian Jiaotong University 2020.
[14]
Li FJ, Zhai YW, Bian Y, et al. Study of plastic deformation behavior on 6061 aluminum alloy. J Plasticity Eng 2015; 22(02): 95-9.
[15]
Fan PF, Liu JS, An HP, Liu LL. Study on high temperature flow stress model of as-cast SA508-3 low alloy steel. Key Eng Mater 2020; 831: 25-31.
[http://dx.doi.org/10.4028/www.scientific.net/KEM.831.25]
[16]
Li CS, He S, Ren J, et al. The flow stress behavior and constitutive model of Cr8Mo2SiV tool steel during hot deformation. Steel Res Int 2020.
[17]
Fu P, Liu X, Dai QS, et al. modification of flow stress curves and constitutive equations during hot compression deformation of 5083 aluminum alloy. J Mater Eng 2017; 45(08): 76-82.
[18]
Wu YF, Li SH, Hou B, et al. Dynamic flow stress characteristics and constitutive model of aluminum 7075-T651. Zhongguo Youse Jinshu Xuebao 2013; 23(03): 658-65.
[19]
Clayton JD. Nonlinear Mechanics of Crystals. Dordrecht: Springer 2011.
[http://dx.doi.org/10.1007/978-94-007-0350-6]
[20]
Rosakis P, Rosakis AJ, Ravichandran G, Hodowany J. A thermodynamic internal variable model for the partition of plastic work into heat and stored energy in metals. J Mech Phys Solids 2000; 48(3): 581-607.
[http://dx.doi.org/10.1016/S0022-5096(99)00048-4]
[21]
Clayton JD. Modeling effects of crystalline microstructure, energy storage mechanisms, and residual volume changes on penetration resistance of precipitate-hardened aluminum alloys. Compos, Part B Eng 2009; 40(6): 443-50.
[http://dx.doi.org/10.1016/j.compositesb.2009.01.009]
[22]
Li HB, Li XL, Xu SC, et al. The flow stress curve correction and constitutive equation of 6082 aluminum alloy under thermal deformation. J Plasticity Eng 2016; 23(03): 152-8.
[23]
Chen ZF. Research on wear, damage and life prediction of friction stir welding tools. PhD thesis; Donghua University 2015.