A model relating tool torque and its associated power and specific energy to rotation and forward speeds during friction stir welding/processing

作者：Cui S; Chen Z W^*; Robson J D

来源：International Journal of Machine Tools and Manufacture, 2010, 50(12): 1023-1030.

DOI：10.1016/j.ijmachtools.2010.09.005

• Friction stir
• Torque
• Decay function
• Material flow resistance

Torque (M) is a very important quantity in the friction stir welding (FSW) process but a satisfactory model relating M to the two major FSW parameters, rotation speed (omega) and forward speed (v), has not been well developed. In this work, a better model of the form, M=f(omega, v), was sought. Experimentally, FSW of an aluminium alloy was conducted over a wide range of omega and v values and M was measured. An exponential decay function has been found to fit all the M versus omega data well and is meaningful for any omega value. The effect of v on M can approximately be accounted for through linearly relating the model parameters to v. The model allows for a detailed evaluation of the sensitivity of M to changes in omega and v. The model decay and the pre-exponential parameters need to be adjusted to make predictions for different aluminium alloys in the low omega range. Both the model and experimental data demonstrate a diminishing alloy effect on material flow resistance as omega increases. Furthermore, models of tool power (P(Tool)) and specific energy (E(s)) can be derived from the model for M and give predictions that are also meaningful over the entire range of omega values. Finally, the dependences of P(Tool) and Es on omega and v and the relationship between E(s) and the processing zone temperature will be discussed.

• 出版日期2010-12