INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 12, DECEMBER 2019 ISSN 2277-8616

Analysis Of Friction Stir Welding Between

Dissimilar Materials Using Bobin Tool
D. Jayabalakrishnan, M.Balasubramanian, P.Prabhu , G.Suganya, C.Ramesh kumar D.B.Naga Muruga

Abstract : Friction stir welding is a solid-state joining process where the original metal characteristics remain unchanged as a whole lot as viable since
joining takes place in a plastic state without melting. FSW tool intermixes the metals at the place of the joint, then softens them and fused using
mechanical strain. It is used most often applied on large pieces of aluminium alloy materials that are impossible and not suitable for further heat
treatment to recover its characteristics. Finite Element Analysis was performed for the Friction Stir Welding process for the joining of dissimilar materials
AA6061 and pure copper by varying the process parameters. For this purpose, a simple model was created for Friction stir Butt-welding Tool and work
pieces to be joined using CREO software and stress analysis is did on them by ANSYS Software.

keywords: Friction Stir Welding; Aluminum; Copper; Butt joint; Finite Element Analysis
————————————————————

1 INTRODUCTION The tool shoulder has tool torque, heat generation,

Friction Stir Welding (FSW) is a solid-state welding process
that is used to produce defect-free and clean welds
between similar and dissimilar materials. Friction stir
welding (FSW) is a solid-state joining method particularly
suited for aluminum alloys, which are difficult to be fusion
welded without hot cracking, porosity or distortion. By this
welding, the placed job is made to be heated at high-
temperature frictionally, therefore it resembles to be more
plastic. Significant microstructure alterations and changes
will be performed, and in result make several local
variations and differences in properties of a weld (i.e.
namely mechanical properties). The basic concept of FSW
is remarkably simple. A rotating tool with a mainly designed
pin and shoulder is slot into the adjoining edges of sheets
or plates to be fixed and consequently passes through
along the joint line-moving front and backside orientations
require knowledge of the tool rotation and travel directions.
In FSW tool revolves in the anti-clockwise direction and the
advancing side is on the right, where the tool travel
direction is opposite the direction of metal flow, and the
retreating side is on the left, where the tool travel direction
is parallel to the direction of metal flow. [1-5] The FSW
contains a welded zone that has a stirred zone also called a
nugget. Generally, a (HAZ) Heat- Affected Zone and
(TMAZ) A Thermo-Mechanically Affected Zone. The stir
zone refers to the zone formerly occupied by the tool pin
used in friction stir processing, where large volumes of
material are processed. This FSW is also said to be the
most efficient welding method to join metals. It is also
considered to be a green technology, economically friendly,
high energy-efficient and versatile. [6-9] A genetic algorithm
is used to evaluate the thermal parameters.
temperature distribution, surface angle and the ratio of the
shoulder radius to pin radius on tool reaction force, and the
size of the weld zone was investigated. The studies were
carried out numerically using the finite-element method.
The welding process used AA2024 aluminum alloy plates
with a thickness of 3 mm. It was also found that the
shoulder angle has very little effect on energy dissipation or
on temperature distribution [10] Double-sided friction stir
welding tool has the support of giving a development zone
in the workpiece to form rectangular in cross-section, as
opposed the triangular zone is more usually found when
conventional friction stir welding tool designs are utilized. A
3D-Model is being applied here for FE experimentation to
assume and predict heat dissipation and based on this, the
history of thermal variations, residual stress dissipation at
the stir zone and the base metal (Al6061-T6) were
predicted [11-13]. The origins of tool shoulder and
geometries on friction stirred aluminum welds by esteem to
weld strength, weld cross-section area, the grain size of
weld and thermo-mechanically affected zone via RSM [14-
18]. FSW process varying pin geometries and speeds is
numerically modeled, and a thermo-mechanically coupled,
rigid-viscoplastic, fully 3-dimensional FEM experiment is
being performed to identify the process variables, the
material flow pattern and observed grain size at the FSW
welded joints. The obtained results finding, optimal tool
geometry and speed for progress nugget integrity of
aluminum alloys. [19-21] It was also observed that
variations in tool path significantly influence the mechanical
and micro structural properties of similar and dissimilar
FSW weld joints and also Tool pin eccentricity played a
considerable role in material mixing and joint qualities of
dissimilar FSW joints which was performed successfully by
.Jayabalakrishnan and Balasubramanian .[22-24]

———————————————— 2.0 Experimental

• D. Jayabalakrishnan, P.Prabhu G.Suganya, C.Ramesh kumar 2.1 Modeling of Friction Stir Welding Parts
D.B.Naga Muruga. is a Faculty of Mechanical Engineering, Sriram Although the Friction Stir Welding Process has many
Engineering College, Tiruvallur, India. Mail:
benefits, it has some drawbacks. One of the drawbacks is a
djayabal2001@yahoo.com
• M.Balasubramanian is a faculty of Mechanical Engineering, R.M.K risk of occurrence of root flaws especially in single-sided
College of Emgineering & Technology, Puduvoyal welds. To avoid these, a double-sided or bobbin tool is
used to remove the root region (fig-1) Modeling of Bobin
tool and aluminum and copper plates were done (fig 1-3).
The design of the assembly view and bobbin tool using

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INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 12, DECEMBER 2019 ISSN 2277-8616

CREO software is shown in (fig (4 & 5). The material
selected for the bobbin tool is a high-speed steel and
threaded tool pin Profile diameter of 4 mm, Shoulder
Diameter is 12mm.was selected in this experiment.
FIG. 5. TOOL DESIGN
Dimensions of Al Plate: Length: 75 mm Width: 50 mm
Height: 4 mm Material: Al 6061 Designed in CREO Bobin
tool used in this experiment Eliminates weld roots, and root
defects There is a less Z direction forces on fixture and
machine. The other benefits are no backing plate’s
required, low distortion, simple control and more tolerance
in thickness variation

2.2 Initial Settings:

FIG. 1. MODEL OF BOBBIN TOOL
There are six analyses done with the followed basic
settings Analysis done in ANSYS Workbench, Analysis
Method used was Explicit Dynamics Model, which was
imported from CREO software. The shape and size of the
Materials were selected as per geometry. There are two
tool speeds to be considered in friction-stir welding with
bobbin tool; how fast the tool rotates and how quickly it
traverses the interface. The discussed two parameters have
major roles and contributions. Therefore, care should be
given to ensure a good efficient welding cycle with a perfect
finish.

 Rotating Speed (Angular Velocity of Tool)

 Transverse Speed (Velocity of Tool)

2.3 Parameters of Analysis

FIG. 2. MODEL OF Cu PLATE Analysis of this experiment was carried out with Ansys
workbench using the method of Explicit dynamics 44 and
the geometry of the model is imported using CREO
software, Analysis was carried out for 3 sets of same
rotational speed with varying transverse speed and three
sets of constant transverse speed with varying rotational
speed. Selected parameters for the experiment is shown in
Table 1
TABLE 1. OVERVIEW OF ANALYSES

FIG. 3. MODEL OF Al 6061 PLATE Rotational

Transverse
Speed
Analysis speed
(Angular
(Velocity)
Velocity)
Analysis
1000 10
1
Analysis
1000 15
2
Analysis
1000 20
3
Analysis
1100 15
4
Analysis
1250 15
FIG. 4. ASSEMBLY VIEW OF WELDING SETUP 5
Analysis
1500 15
3 6 Results
and Discussion
Maximum Stress-induced and strain deformation are
studied in the analysis of Aluminum work piece , Copper
work piece and also for bobbin tool in six different
conditions and results are tabulated Maximum Stress in
Al6061 plate on Analysis 2 is 0.054 MPa, Maximum Strain
in Al6061 plate on Analysis 2 is 7.93E-7(fig6 a & b).
Maximum Stress in Cu plate on Analysis 2 is 0.097 MPa,
Maximum Strain in Cu plate on Analysis 2 is 9.46E-7(fig7 a

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& b). Maximum Stress in Bobbin Tool on Analysis 2 is 53.83

MPa, Maximum Strain in Bobbin Tool on Analysis 2 is
3.46E-4 (fig8 a & b)

FIG 8 A & B ANALYSIS RESULTS OF ANGULAR

VELOCITY : 1000RPM & VELOCITY : 15 MM/S : BOBIN
TOOL

FIG 6 A & B ANALYSIS RESULTS OF ANGULAR TABLE 2: TABULATION OF ANALYSIS RESULTS

VELOCITY: 1000RPM & VELOCITY: 15 MM/S : AL 6061
PLATE
Ang Al 6061 Plate Cu Plate Tool
ular Velo
Velo city Max.S Max.S Max.S Max.S Max.S Max.S
city tress train tress train tress train

RP mm/
Mpa Mpa Mpa
M s
100 7.81E 0.100 9.53E 5.10E
10 0.056 71.93
0 -07 3 -07 -04
100 7.93E 9.40E 3.46E
15 0.054 0.097 53.83
0 -07 -07 -04
100 8.16E 0.092 8.97E 2.73E
20 0.054 56.29
0 -07 7 -07 -04
100 7.93E 9.40E 3.46E
15 0.054 0.097 53.83
0 -07 -07 -04
110 8.47E 9.30E 2.92E
15 0.059 0.102 60.28
0 -07 -07 -04
125 8.81E 9.28E 4.49E
15 0.063 0.107 90.4
0 -07 -07 -04
150 9.21E 9.71E 162.8 8.21E
15 0.066 0.113
0 -07 -07 1 -04

4. Conclusions
FIG 7 A & B ANALYSIS RESULTS OF ANGULAR  Considering the above results, the welding, this
VELOCITY : 1000RPM & VELOCITY : 15 MM/S : CU has the parameters Rotational speed of 1000RPM
PLATE and Transverse speed of 15mm/s, results relatively
good max. Stress and max. Strain for Bobbin tool
as 53.83MPa and 3.46E-04
 In this condition, the max. Stress and max. Strain
of the CU and Al 6061 Plates are a comparatively
good one.
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 The parameters of the above-mentioned condition
are better one for friction stir welding with the
threaded pin profiled Bobin tool.
 With the above-resulted condition, the bobbin tool
may have more life, due to the comparatively low
max. Stress and strain on the bobbin tool. The
expected tool life is 1E6 cycles, which is found by
fatigue analysis.
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