Mathematical Model for Multi-Component Forces and Torque Determination

in Friction Stir Welding

Jauhari T.K.
1, a
, I.P Almanar.
2, b
, Zuhailawati H.
3, c

1, 2
School of Mechanical Engineering, Universiti Sains Malaysia, 14300 Nibong Tebal, Penang.
Malaysia
3
School of Material Engineering and Natural Resources, Universiti Sains Malaysia, 14300 Nibong
Tebal, Penang. Malaysia
a
jtk10_mec006@student.usm.my,
b
meinput@yahoo.co.uk,
c
zuhailawati@yahoo.com
Keywords: friction stir welding; mathematical; model; multi-components; forces; torque;
Abstract Major works concentrated on the energy conversion from mechanical friction work to
heat; emphasized on the immediate contact surface of work material and rotating welding tool but
with no in-depth analytical study to relate the loads that are transferred to the work material and the
welding fixture especially at early stage of heat generation. In this work, a mathematical model is
developed to predict three-dimensional force components and axial torque of the rotating tool based
on contact mechanic principle in relation to Al6061 temperature-dependent material properties. The
model shows the ability to be possibly adapted for different metallic material and physical
properties. It suggests the exerted torque and loads calculation endured by work material involving
friction and shear mechanism of two static-dynamic contacting surface; rotating rotational tool and
the fixed work material, to be used as one of the option for optimization of the welding process such
as to determine the ratio of slip, non-slip contact condition through comparisons of experimental
and computer simulation on the Friction Stir Welding process.
Introduction
Friction stir welding (FSW) gained much attention in research and manufacturing since the
introduction in 1991[1]. The main feature of this solid state welding is that it allows a lower
temperature and heat input than conventional welding without producing sparks or flames. In this
regards, FSW make possible to join light and difficult to weld material such as aluminium,
magnesium, copper or titanium and greatly influence their usage in structural applications [2]. FSW
provides good quality and strong weldment with less number of equipment, eliminates the use of
filler metal and successfully employed to the aerospace, automobile and ship building industry [3].
Vast works has been made to understand the physical process that influences the variables
associated to FSW using empirical and numerical models. Frigaard et al. [4] modelled heat
generation based on the torque required to rotate a circular shaft relative to the material surface
assuming constant coefficient of friction, pressure distribution and full conversion of shearing work
to heat. Pew et al. [5] established welding power model to determine the overall heat input
calculated from spindle torque through the relationship between the rotational speed and the
represented torque derived associates to the key parameters. In detail, Nandan et al. [6] investigated
the visco-plastic flow and heat transfer from heat source due to interfacial heat generation at tool-
workpiece interface and plastic deformation away from the interface. It is defined by the contact
area, radius of the tool pin and shoulder, shear stress, spatial coefficient of friction, angular velocity
and the exerted normal pressure, validated through comparison of the experimental study to the
computed heat generation and the total torque exerted on the tool. Schmidt [7] and Colegrove et al.
[8] developed heat generation model characterized by the contact condition at the interface
described as sliding, sticking or partial sliding-sticking that experimentally determined by the
plunge force and torque from the FSW process. Hamilton et al. [9] developed a thermal model that
utilized slip factor derived empirically to observe the welding energy and temperature from torque
based heat input. Soundarajan et al. [10] simulated a thermo-mechanical model with adaptive
boundary condition to predict temperature profile, developed stresses and the three-dimensional
force components.
Significantly, these models represent the correlation of the independent variables of FSW
welding parameters. Though, no in-depth analytical study to relate the load applied on the rotating
tool and load that is transferred to the work material especially at the early stage of the heat
generation. In the present work, mathematical model is developed to predict three-dimensional
force component and torque on the work material temperature-dependent material properties,
derived in matrix to simulate the exerted axial and centrifugal load of the rotating tool being
distributed onto the fixed work material.
To determine the effect of the welding parameters toward the success of defect free welding
during the FSW process, a lot of interrelated parameters need to be accessed in order to have the
most optimum process hence the controlling boundaries are to be recognized in form of measurable
unit that affecting each other.
Methodology
Two Al6061-T6 plates dimensioned 100 X 200 mm each were arranged abutted. High speed
steel (HSS) tool with pin diameter 6 mm, 2 tapered, 5mm height and 18 mm diameter flat
shoulder. The pin and shoulder diameter make 1:3 ratio and is tilted 2 away from the vertical axis
toward the trailing side. During the plunging process, the rotating tool pin is axially forced on the
workpiece surface, sliding and later converted into heat. The conversion of mechanical work of the
rotating tool is represented in equation Eq. 3 and Eq. 4. Upon the plasticizing of work material
around the pin, the heat generation is partially generated by plastic deformation due to prompt
internal shearing while friction heating continues to contribute heat to the work.

Fig. 1: Work envelope represents associated loads on measuring reference points during FSW
Model Description
Assumptions
The model is based on the assumptions that heat generation is at initial phase where contact
condition between rotating tool and the immediate contact surface is sliding with constant rate.
Plunged force and tool angular velocity are the manipulative parameters that affect the total energy
conveyed into the workpiece.
Total tools torque is represented by the function of uniform shear stress due to normal load
on contact surface area and friction coefficient of 0.4. Though coefficient of friction is differs in
time and space for different materials properties especially with temperature, the value remain
constant prior reaching solidus temperature of material due to the material pairings as explained by
Popov [11]. Vertical loading in FSW is modelled as function of pressure distribution P(T),
correlated from temperature dependent material properties of Al6061-T6 [12];
. 537 315
315 100
100 9 . 23
1 . 114 35 . 0
08 . 66 41 . 4 03 . 0 9 9
11 . 124
) (
2 3 5 4 8
C T
C T
C T
T
T T T E T E T P
< s
< s
< s

+
+ + =

(1)
The maximum temperature is 0.6 of Al6061-T6 melting temperature, T
m
which is falls in work
hardening temperature region below the solidus temperature [9, 10].
Mathematical Model
Initial heat generation takes place from the first contact of the rotational tool pin and continues
throughout the plunging phase. The interface heat generation is constant with consideration of
constant rotational speed, temperature dependent pressure distribution and constant coefficient of
friction. Based on Fouriers 2
nd
law [13];
.
2
2
2
2
2
2
q
z
T
y
T
x
T
k
t
T
c
p
+
|
|
.
|

\
|
c
c
+
c
c
+
c
c
=
c
c
p (2)
where c
p
is heat capacity, x, y, and z are the space coordinate and is the heat source term. The
torque required to rotate the rotational tool relative to the static workpiece surface is given [14, 15];
.
3
2
2 ) (
3
0 0
PR dr T P dM M
R M
R
vt t u = - = =

(3)

where M is interfacial torque, is coefficient of friction and R is contact surface radius. The friction
work is converted into frictional heat [16];
.
3
2
2 ) (
3
0
2
0
PR dr r T P dM q
R M
R
eut t eu e = - = =

(4)
where is net power. Apparently, heat input depends on normal pressure distribution, contact
surface radius, coefficient of friction and rotational speed, transferred into work material and thus
characterized the process variable for FSW. In order to understand FSW in expression of
mechanical loading, the model is derived from Fig.1;
. ) (
1 1 1 1
k z j y i x x r + + = (5)
. ) (
2 2 2 2
k z j y x x r + = (6)
. ) (
3 3 3 3
k z j y i x x r = (7)
. ) (
4 4 4 4
k z j y i x x r + = (8)
r
1
, r
2
, r
3
and r
4
are positional vector for four measurement references in relation to the tool position
on the workpiece for a set of Cartesian coordinate of the tool. The sum of forces acting in FSW
responds on the temperature dependent material properties is calculated at static equilibrium;
.
4
1
, , , ,
=
-
=
n
z y x z y x
Fn F (9)
. ) (
) ( ) ( cos sin
4 4 3 3 2 2 1 1
4 3 3 1 4 3 2 1 4 3 2 1
k z F F z F F z F F z F F
j y F y F y F y F i F F F F F F F F k F i F
z z z z
x x x x x x x x
+ + + + + +
+ + + + + + + = +
- - - -
- - - - - -
u u
(10)

where F*, is plunge force in the function of contact surface area and under the temperature
dependent pressure distribution and F represent the reaction forces. The torque exerted on the
workpiece by the rotating tool is calculated based on Eq. 3 and coupled by the moments acted at
each of the measuring references on the workpiece as in Fig. 1;
.
4
1
, , , , , ,
=
-
=
n
z y x z y x z y x
Fn rn M (11)
Where;
.
4 3 2 1
M M M M = = = (12)

The moment exerted is in equilibrium and the acting forces exerted by the rotational tool
mechanism are determined from Eq. 11, generally;
.
4
1
, , , , , , z y x z y x z y x
Fn Rn M =
-
; n = 1, 2.., 4. (13)
. ) ( ) ( ) ( k Fn y Fn x j Fn z Fn x i Fn z Fn y F r
x n y n x n z n y n z n n n
+ + + = (14)
In order to describe the reaction forces, the matrix representation of the linear equations is solved
using Gauss Elimination Method. At static equilibrium, the moment at each of the measuring
reference remain the same.

(a) (b)
Fig. 2: (a) Applied plunged force compares to reaction forces and torque from Eq. 10, 11; (b) Reaction
forces exerted on the measuring references from the rotating tool from Eq. 14, Fig. 1
Result and Discussion
Closer approximation is made on the geometry of the workpiece to measure reaction forces and
moment from FSW, thus reducing Eq. 14 by performing co-planar analysis.
Under constant heat generation rate, the value for the pressure distribution exerted on the
rotating tool remain constant throughout the plunging process until it reaches desired depth
proportionally with the increase of cross-sectional radius. Thus, Fig. 2a shows the torque profile at
temperatures during the plunging process. The effect of rotating tool and plunging process on the
reaction forces and moment influence stress distribution on the workpiece and for soft material
Al6061-T6, the reaction forces measured during the plunging phase at measuring reference are in
small magnitudes as in Fig. 2b due to the temperature-dependent material properties. In addition,
Fig. 2b shows the asymmetry properties of the process which favour to the direction of tool rotation.
The stress distribution during the plunging phase increases rapidly proportionally to the
increase of tool radius. It is in agreement to the heat generation rate and transient effect prior
reaching peak temperature of about 0.6T
m
of work material with highest thermal conductivity and
low strength that measure the degree of softness or malleability of the material.
0
20
40
60
80
100
0
5
10
15
20
25
30
35
0 100 200 300 400
T
o
r
q
u
e
,

N
m

P
l
u
n
g
e

F
o
r
c
e
,

k
N

C
Plunge Force Fz Fx Torque
-10
-5
0
5
10
0 100 200 300 400
R
e
a
c
t
i
o
n

F
o
r
c
e
,

k
N

C
Rx1 Ry1 Rx2 Ry2 Rx3 Ry3 Rx4 Ry4 Rx,Ry
Conclusion
Lots of interrelated parameters need to be studied in order to have defect free and optimum process.
Controlling boundaries are to be recognized in form of measurable unit that affecting FSW
parameter. Active stresses and associated moment exerted in the workpiece during FSW lead to the
flow characteristic of material around the pin. The present paper develops numerical model based
on contacts mechanics principle to predict multi-component forces and torque exerted on the work
material during FSW. Mathematical model is derived based on references within the three
dimensional parameter of interest represents by a matrix. Forces and torque related to FSW is
determined by assuming uniform contact between tool and the contact surface and the results of the
model shows the ability to be possibly adapted for different material. Thus the exerted torque and
loads calculation endured by work material involved mechanical friction and shear mechanism
between two contacting surface can be used as option for optimization of the FSW as well as to
determine the pin to shoulder ratio and contact condition.
Acknowledgement
This present work is supported by Universiti Sains Malaysia through RU-Grant (814084), USM
Institute of Postgraduate Studies Graduate Research Fund (IPS-GRF) and USM-Fellowship
schemes, which are greatly acknowledged.
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