Identifying friction stir welding process parameters through coupled numerical and experimental analysis

Research output: Contribution to journalConference Contribution

6 Citations (Scopus)

Abstract

Friction Stir Welding (FSW) is a complex thermal-mechanical process. Numerical models have been used to calculate the thermal field, distortion and residual stress in welded components but some modeling parameters such as film coefficient and thermal radiation of the work pieces may be technically difficult and/or expensive to measure experimentally. Therefore, it is important to establish a systematic procedure to identify FSW process parameters. In this paper, a simplified finite element model for analysis of a FSW thermal progress is proposed in which two parameters, tool heat input rate and heat loss through the backing plate, are identified as parameters for optimization through application of a generic algorithm. A genetic algorithm is used to evaluate the two thermal parameters. By comparing the FEM numerical results with experimental results, the FSW process thermal parameters have been successfully identified. This automatic parameters characterization procedure could be used for the FSW process optimization.

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Friction stir welding
Heat radiation
Heat losses
Hot Temperature
Numerical models
Residual stresses
Genetic algorithms
Finite element method

Keywords

  • friction stir welding
  • genetic algorithms
  • automatic parameter identification
  • numerical modelling
  • Python

Cite this

@article{d3e01b970a5d48f6b31ea0b4e6147813,
title = "Identifying friction stir welding process parameters through coupled numerical and experimental analysis",
abstract = "Friction Stir Welding (FSW) is a complex thermal-mechanical process. Numerical models have been used to calculate the thermal field, distortion and residual stress in welded components but some modeling parameters such as film coefficient and thermal radiation of the work pieces may be technically difficult and/or expensive to measure experimentally. Therefore, it is important to establish a systematic procedure to identify FSW process parameters. In this paper, a simplified finite element model for analysis of a FSW thermal progress is proposed in which two parameters, tool heat input rate and heat loss through the backing plate, are identified as parameters for optimization through application of a generic algorithm. A genetic algorithm is used to evaluate the two thermal parameters. By comparing the FEM numerical results with experimental results, the FSW process thermal parameters have been successfully identified. This automatic parameters characterization procedure could be used for the FSW process optimization.",
keywords = "friction stir welding , genetic algorithms, automatic parameter identification, numerical modelling, Python",
author = "Xingguo Zhou and Wenke Pan and Donald Mackenzie",
year = "2013",
month = "8",
doi = "10.1016/j.ijpvp.2013.04.001",
language = "English",
volume = "108-109",
pages = "2–6",
journal = "International Journal of Pressure Vessels and Piping",
issn = "0308-0161",
number = "Aug-Sep",

}

Identifying friction stir welding process parameters through coupled numerical and experimental analysis. / Zhou, Xingguo; Pan, Wenke; Mackenzie, Donald.

In: International Journal of Pressure Vessels and Piping, Vol. 108-109, No. Aug-Sep, 08.2013, p. 2–6.

Research output: Contribution to journalConference Contribution

TY - JOUR

T1 - Identifying friction stir welding process parameters through coupled numerical and experimental analysis

AU - Zhou, Xingguo

AU - Pan, Wenke

AU - Mackenzie, Donald

PY - 2013/8

Y1 - 2013/8

N2 - Friction Stir Welding (FSW) is a complex thermal-mechanical process. Numerical models have been used to calculate the thermal field, distortion and residual stress in welded components but some modeling parameters such as film coefficient and thermal radiation of the work pieces may be technically difficult and/or expensive to measure experimentally. Therefore, it is important to establish a systematic procedure to identify FSW process parameters. In this paper, a simplified finite element model for analysis of a FSW thermal progress is proposed in which two parameters, tool heat input rate and heat loss through the backing plate, are identified as parameters for optimization through application of a generic algorithm. A genetic algorithm is used to evaluate the two thermal parameters. By comparing the FEM numerical results with experimental results, the FSW process thermal parameters have been successfully identified. This automatic parameters characterization procedure could be used for the FSW process optimization.

AB - Friction Stir Welding (FSW) is a complex thermal-mechanical process. Numerical models have been used to calculate the thermal field, distortion and residual stress in welded components but some modeling parameters such as film coefficient and thermal radiation of the work pieces may be technically difficult and/or expensive to measure experimentally. Therefore, it is important to establish a systematic procedure to identify FSW process parameters. In this paper, a simplified finite element model for analysis of a FSW thermal progress is proposed in which two parameters, tool heat input rate and heat loss through the backing plate, are identified as parameters for optimization through application of a generic algorithm. A genetic algorithm is used to evaluate the two thermal parameters. By comparing the FEM numerical results with experimental results, the FSW process thermal parameters have been successfully identified. This automatic parameters characterization procedure could be used for the FSW process optimization.

KW - friction stir welding

KW - genetic algorithms

KW - automatic parameter identification

KW - numerical modelling

KW - Python

UR - http://www.scopus.com/inward/record.url?scp=84881254747&partnerID=8YFLogxK

UR - http://dx.doi.org/10.1016/j.ijpvp.2013.04.001

UR - http://www.sciencedirect.com/science/article/pii/S0308016113000574

U2 - 10.1016/j.ijpvp.2013.04.001

DO - 10.1016/j.ijpvp.2013.04.001

M3 - Conference Contribution

VL - 108-109

SP - 2

EP - 6

JO - International Journal of Pressure Vessels and Piping

T2 - International Journal of Pressure Vessels and Piping

JF - International Journal of Pressure Vessels and Piping

SN - 0308-0161

IS - Aug-Sep

ER -