Abstract

Adequate heat input provided by the proper combination of friction stir welding (FSW) parameters is critical to sound welding. Optimum parameter setting requires exhaustive trials and extensive experiments, which require considerable time, resources, and cost. This study uses simulation and modelling approaches to generate three significant tool-work heat flux generating interfaces (tool shoulder, lateral and bottom surfaces of the pin). The temperature data was acquired by performing nine experiments on 4 mm thick AA6060-T5 sheets. The effects of significant FSW parameters (Tool Rotational Speed (TRS) and welding speed (WS)) on the heat input were modelled. The calculated heat input rates at the shoulder and pin surfaces (Q₁, Q₂, and Q₃) were numerically estimated. The experimental data was converted into a mathematical model using the response surface method to study the effect of welding parameters on heat input from each of the three surfaces. The analysis of the results showed that among three interfaces, the shoulder provides the most significant heat input due to the immense friction between this surface and the parts to be welded. The interaction between the main factors produced little heat on the three surfaces. The ANOVA test showed that the three models are a good approximation of the results of both experiments and theories.

中文翻译：

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搅拌摩擦焊过程中工具-工作界面的热建模

摘要

搅拌摩擦焊 (FSW) 参数的适当组合提供的充足热输入对于良好焊接至关重要。最佳参数设置需要详尽的试验和广泛的实验，这需要大量的时间、资源和成本。本研究使用仿真和建模方法来生成三个重要的工具工作热通量生成界面（工具肩部、销的侧面和底面）。温度数据是通过在 4 毫米厚的 AA6060-T5 板上进行九次实验获得的。模拟了重要的 FSW 参数（工具转速 (TRS) 和焊接速度 (WS)）对热输入的影响。计算出的肩部和销表面的热输入率（Q ₁、Q ₂和Q₃）进行了数值估计。使用响应面法将实验数据转换为数学模型，以研究焊接参数对三个表面中每一个的热输入的影响。结果分析表明，在三个界面中，肩部提供了最显着的热输入，因为该表面与要焊接的零件之间存在巨大的摩擦力。主要因素之间的相互作用在三个表面上产生的热量很少。ANOVA 检验表明，这三个模型很好地近似了实验和理论的结果。