Simulation of Tool Rotation and Travelling Speed Effects on Friction Stir Welding of Ti-6Al-4V

In this research, the effects of parameters include tool rotational and traverse speeds were investigated on heat generation and material flow during friction stir welding of Ti-6Al-4V alloy with computational fluid dynamics (CFD) method. Simulation results showed that with increasing of tool rotational and decreasing tool traverse speed, the more frictional heat generates which causes formation of bigger stir zone. Results indicate that the rotation of the shoulder can accelerate the material flow behavior near the top surface. The temperature field in the friction stir welding of Ti-6Al-4V alloy was anti symmetric to the welding line. Due to the results the heat generation and temperature distribution at advancing side were more than retreating side in all joint conditions. According to the results unsmooth and disarray flow patterns were formed in stir zone which caused formation of banded layer structure in advancing side. Due to results the torque decreases with an increase in the tool rotation speed due to increases in the heat generation rate and temperature, but torque is not significantly affected by the change in welding speed. The computed pressure field was higher in front of the tool compared to the trailing edge, and it is because pressure difference is required for flow occur. According to the selected parameters in this study, maximum temperature was produced in 800rpm tool speed and the computed strain rate and pressure of workpiece in this speed were 2.3 s-1, 0635 MPa, respectively.