05
Process Parameter Optimization in Friction Stir Processing
A 3D thermomechanical finite element model of friction stir processing on Aluminium 5083, used to study how tool parameters drive temperature and stress.
- FEA
- Thermal Analysis
- Process Simulation
- Material
- Al 5083
- Peak temperature
- 389 °C
- Test cases
- 4
Overview
- Simulation-based alternative to costly experimental trials
- Modeled plunging, preheating, and tool traverse stages
- Peak temperature of 389 °C identified
Simulation methodology
I built the model in ANSYS Workbench 18.1 and ran a parametric study on tool rotational speed, traverse speed, and plunge depth.
| Test | Rotation (RPM) | Traverse (mm/min) | Plunge (mm) |
|---|---|---|---|
| 1 | 200 | 60 | 0.2 |
| 2 | 500 | 60 | 0.2 |
| 3 | 200 | 40 | 0.2 |
| 4 | 200 | 60 | 0.5 |
Results
- Strong correlation between process parameters and temperature distribution
- Higher plunge depth and rotational speed increased residual and frictional stresses
- Simulation-driven tuning can improve weld quality and reduce defects
